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N
N11
Technical Guidance Reference
Technical Guidance
Turning Edition ................................................ N12
Milling Edition ................................................. N17
Endmilling Edition ........................................... N21
Drilling Edition ................................................. N24
SUMIBORON Edition ...................................... N29
References
SI Unit Conversion List ................................... N33
Metals Symbols Chart (Excerpt) .................... N34
Steel and Non-Ferrous Metal Symbol Chart (Excerpt) ... N35
Hardness Scale Comparison Chart .............. N36
Standard of Tapers ......................................... N37
Dimensional Tolerance of Standard Fittings ... N38
Dimensional Tolerance and Fittings .............. N40
Surface Roughness ........................................ N41
References
N
Parts
Technical Guidance Reference
N11 to N41 N
N12
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øDm
n
a p
f
f
h
RE
■ Relation between cutting speed and cutting force
1,600
800
0240160800
Prin
cip
al F
orce
(N)
Cutting Speed (m/min)
Rake Angle: -10°
Rake Angle: 0°
■ Relation between rake angle and cutting force
1,600
2,000
2,400
2,800
20 10 0 -10 -20
Prin
cip
al F
orce
(N)
Rake angle (degrees)
2,000
4,000
6,000
8,000
0 0.10.04
0.2 0.4
Sp
ecifi
c cu
ttin
g fo
rce
(MP
a)
Feed Rate f (mm/rev)
Traverse Rupture Strength
800MPa
600MPa
400MPa
When feed rate decreases, specific cutting force increases.
■ Relation between feed rate and specific cutting force (for carbon steel)
500
1000
1500
3500
4000
0.4 0.8 1.2 1.6
Cut
ting
Forc
e (N
)
Nose Radius (mm)
Principal Force
Feed Force
Back Force
Large nose radius increases back force.
■ Relation between nose radius and 3-part force
Work Material: SCM440 (38HS)Insert: TNGA2204 ○○Holder: PTGNR2525-43Cutting Conditions: vc =100m/min, ap = 4mm, f = 0.45mm/rev
■ Three cutting force components
P = k c×q1,000
= k c×a p×f
1,000
P : Cutting force (kN)k c : Specific cutting force (MPa)q : Chip area (mm2)a p : Depth of Cut (mm)f : Feed Rate (mm/rev)
● Calculating cutting force
Fc : Principal force Ff : Feed force Fp : Back force
Ff
Fp
Fc
● Theoretical (geometrical) surface roughness
■ Machined Surface Roughness
● Ways to improve surface finish roughness
(1) Use an insert with a larger nose radius
(2) Optimise the cutting speed and feed rate
so that built-up edges do not occur
(3) Select an appropriate insert grade
(4) Use wiper insert
■ Actual surface roughnessSteel: Theoretical surface roughness × 1.5 to 3 Cast iron: Theoretical roughness × 3 to 5
h = f 2
× 103
8×RE
h: Theoretical surface roughness (μm)
f : Feed rate per revolution (mm/rev)
RE: Nose radius (mm)
Pc : Power requirements (kW)vc : Cutting speed (m/min)f : Feed Rate (mm/rev)
ap : Depth of cut (mm)kc : Specific cutting force (MPa)H : Required horsepower (HP)
V : Machine efficiency(0.70 to 0.85)
■ Calculating Power Requirements
● Rough value of kc
Aluminum: 800MPa General steel: 2,500 to 3,000MPa Cast iron: 1,500MPa
Pc =vc×f×a p×k c60×103×V
H = Pc
0.75
■ Calculating Cutting Speed
· n : Spindle speed (min -1)
· vc : Cutting speed (m/min)
· f : Feed rate per revolution (mm/rev)
· ap : Depth of cut (mm)
·Dm : Diameter of workpiece (mm)
Feed Direction
n : Spindle Speed (min-1)vc : Cutting speed (m/min)Dm : Inner/outer diameter of workpiece (mm)
X : π ≈ 3.14
(1) Calculating rotation speed from cutting speed
Refer to the above table
(2) Calculating cutting speed from rotational speed
Example: vc=150m/min, Dm=100mm
n =1,000×150
= 478 (min-1)3.14×100
n = 1,000×vc
X×Dm
vc =X × Dm × n
1,000
Technical Guidance
The Basics of Turning, Turning Edition
N13
References
N
Parts
Technical Guidance Reference
■ Forms of Tool FailureClassification No. Name of Failure Major Causes of Failure
Failure Caused by Mechanical
Factors
(1) to (5) (6) (7)
Flank Wear Chipping Fracture
Wear caused by the scratching effect of hard grains contained in the work material Fine breakages caused by high cutting loads or vibration Large breakage caused by the impact of an excessive mechanical force acting on the cutting edge
Failure Caused by
Thermal and Chemical Reactions
(8) (9) (10) (11)
Crater wear Plastic deformation Thermal cracking Built-up edges
Cutting chips removing tool material as it flows over its top rake at high temperatures Deformation of cutting edge due to softening at high temperatures Fatigue from rapid, repeated heating and cooling cycles during interrupted cutting Work material is pressure welded on the top face of the cutting edge
■ Tool Wear Curve
· This double logarithm graph shows the relative tool life (T) with the specified wear over a range of cutting speeds (Vc) on the X axis, and the cutting speed along the Y axis
■ Tool Life (V-T)
Flank wear Crater wear on rake faceFl
ank
Wea
r W
idth
(VB) (
mm
)
Cutting Time (T) (min)
Initial wear
Steady wear
Sudden increase in wear
Cra
ter
Wea
r D
epth
(KT)
(mm
)
Cutting Time (T) (min)
· Wear increases rapidly right after starting cutting, then moderately and proportionally, and then rapidly again after a certain value
· Wear increases proportionately to the cutting time
Flank Wear Crater wear
Tool
wea
r
Flan
k W
ear W
idth
(mm)
Cutting Time (min)
VB
vc1
T1 T2 T3 T4
vc2 vc3
vc4
Cra
ter W
ear D
epth
(mm
)
Cutting Time (min)
KT
vc1
T'1 T'2 T'3 T'4
vc3 vc4vc2
Tool
life
Cut
ting
Spe
ed (m
/min
)
Lifetime (min)
Invc1Invc2Invc3Invc4
InT1 InT2 InT3 InT4
Cut
ting
Spe
ed (m
/min
)
Lifetime (min)
Invc1
Invc2
Invc3
Invc4
InT'1 InT'2 InT'3 InT'4
Forms of Tool Wear
Burrs occur
Higher cutting force
Poor surface roughness
Edge wear VC
Long chipsFracture due to decreased strength
Poor dimensional accuracyBurrs occur
Side flank wearVN1
Flank Wear
Rake Face Wear
Average flank wear VB
Face flank wearVN2
Crater wear KT
(9)
(11)(4)(10)
(6)(3)(2)
(10)
(8)
(1)(7)
(5)
Technical Guidance
Forms of Tool Failure and Tool Life, Turning Edition
N14
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■ Insert Failure and Countermeasures
Insert Failure Cause Countermeasures
Flank Wear
· Tool grade lacks wear resistance · Cutting speed is too fast · Feed rate is far too slow
· Select a more wear-resistant grade P30 → P20 → P10 K20 → K10 → K01
· Increase rake angle· Decrease cutting speed · Increase feed rate
Crater Wear
· Tool grade lacks crater wear resistance · Rake angle is too small · Cutting speed is too fast · Feed rate and depth of cut are too large
· Select a more crater wear-resistant grade· Increase rake angle · Change the chipbreaker of the insert · Decrease cutting speed · Reduce feed rate and depth of cut
Cutting Edge Chipping· Tool grade lacks toughness
· Cutting edge breaks off due to chip adhesion
· Cutting edge is not strong enough · Feed rate and depth of cut are too large
· Select a tougher grade P10 → P20 → P30 K01 → K10 → K20
· Increase amount of honing on cutting edge
· Reduce rake angle· Reduce feed rate and depth of cut
Cutting Edge Fracture · Tool grade lacks toughness · Cutting edge is not strong enough · Holder is not strong enough · Feed rate and depth of cut are too large
· Select a tougher grade P10 → P20 → P30 K01 → K10 → K20
· Select an insert chipbreaker with a strong cutting edge
· Select a holder with a larger approach angle
· Select a holder with a larger shank size · Reduce feed rate and depth of cut
Adhesion/Built-up Edges· Inappropriate grade selection · Cutting edge is not sharp enough · Cutting speed is too slow · Feed rate is too slow
· Select a grade with less affinity to the work material Coated carbide or cermet grades
· Select a grade with a smooth coating · Increase rake angle · Reduce honing · Increase cutting speed · Increase feed rate
Plastic Deformation
· Tool grade lacks thermal resistance · Cutting speed is too fast· Feed rate and depth of cut are too large · Not enough coolant
· Select a more crater wear-resistant grade· Increase rake angle · Decrease cutting speed · Reduce feed rate and depth of cut · Supply sufficient coolant
Notch Wear
· Tool grade lacks wear resistance · Rake angle is too small · Cutting speed is too fast
· Select a more wear-resistant grade P30 → P20 → P10 K20 → K10 → K01
· Increase rake angle · Alter depth of cut to shift the notch location
Technical Guidance
Cutting Edge Failure and Countermeasures, Turning Edition
N15
References
N
Parts
Technical Guidance Reference
■ Type of Chip GenerationFlowing Shearing Tearing Cracking
Typ
e
Work Material Work Material Work Material Work Material
Con
diti
on Continuous chips with good surface finish
Chip is sheared and separated by the shear angle
Chips appear to be torn from the surface
Chips crack before reaching the cutting point
Appli
catio
n
General cutting of steel and light alloy
Steel, stainless steel (low speed)
Steel, cast iron (very low speed, very small feed rate)
Cutting of general cast iron and carbon
Influ
ence
fact
or
■ Factor of Improvement of Chip Control
(1) Increase feed rate (f )
f1
t1t1
f2
t2t2
f: : When f2 > f1, t2 > t1
When the feed rate increases, the chip thickness (t) increases and chip control improves.
(2) Decrease side cutting edge (:)
f f
t1 t2
θ1:1θ2:2
:When :2 < :1, t2 > t1
Even if the feed rate is the same, a smaller side cutting edge angle makes chips thicker and chip control improves.
(3) Reduce nose radius (RE)
f f
RE1 RE2
t2
CornerSmall radius
CornerLarge radius
t1t1t2
RE: When RE2 < RE1, t2 > t1
Even if the feed rate is the same, a smaller nose radius makes chips thicker and chip control improves.
* Cutting force increases proportionately to the length of the contact surface. Therefore, a larger nose radius increases back force which induces chattering. A smaller nose radius produces a rougher surface finish at the same feed rate.
■ Type of Chip Control
Classification of
chip shapes
Depth of cut A B C D E
Large
Small
Eval
uatio
n NC lathe (for automation) H H S S JGeneral-purpose lathe (for safety) H S S S to J H
Good: C type, D typeA type: Twines around the tool or workpiece, damaging the machined
surface and affecting safetyPoor B type: Causes problems in the automatic chip conveyor and chipping occurs easily
E type: Causes spraying of chips and poor surface finish due to chattering, along with chipping, large cutting force and high temperatures
{D
epth
of C
ut a
p (m
m)
4 .0
2.0
0.1 0.2 0.3 0.4 0.5
Feed Rate f (mm/rev)
Sid
e C
uttin
g E
dge
45°
15°
0.2 0.25 0.3 0.35
Feed Rate f (mm/rev)
Nos
e R
adiu
s (m
m)
1 .6
0.8
0.4
0.5 1.0 1.5 2.0
Depth of Cut ap (mm)
Large Large Small Large
Deformation of work material Rake angle
Depth of cut Cutting speed
Small Small Large Small
Technical Guidance
Cutting Edge Failure and Countermeasures, Turning EditionTechnical Guidance
Chip Control and Countermeasures, Turning Edition
N16
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■ Thread Cutting Methods
Cutting Method FeaturesRadial Infeed
· Most common threading technique, used mainly for small pitch threads. · Easy to change cutting conditions such as depth of cut, etc. · Long contact point has a tendency to chatter. · Chip control is difficult. · Considerable damage tends to occur on the trailing edge side.
Flank Infeed
· Effective for large-pitch threads and blemish-prone work material surfaces. · Chips evacuate from one side for good chip control. · The trailing edge side is worn, and therefore the flank is easily worn.
Modified Flank Infeed
· Effective for large-pitch threads and blemish-prone work material surfaces. · Chips evacuate from one side for good chip control. · Inhibits flank wear on trailing edge side.
Alternating Flank Infeed
· Effective for large-pitch threads and blemish-prone work material surfaces. · Wears evenly on right and left cut edges. · Since both edges are used alternately, chip control is sometimes difficult.
Direction of Depth of Cut
Feed Direction
LeadingEdge
TrailingEdge
■ Troubleshooting for Threading
Failure Cause Countermeasures
Cut
ting
Ed
ge D
amag
e
Excessive Wear · Tool grade · Select a more wear-resistant grade
· Cutting conditions· Reduce cutting speed · Use a suitable quantity and concentration of coolant · Change the number of passes
Uneven Wear on Right and Left Sides
· Tool mounting· Check whether the cutting edge inclination angle is
appropriate for the thread lead angle· Check whether the tool is mounted properly
· Cutting conditions· Change to modified flank infeed or alternating flank infeed
Chipping · Cutting conditions · If built-up edge occurs, increase the cutting speed
Breakage · Biting of chips · Supply enough coolant to the cutting edge
· Cutting conditions· Increase the number of passes and reduce the depth of cut for each pass
· Use separate tools for roughing and finishing
Sha
pe
and
Acc
urac
y
Poor Surface Roughness · Cutting conditions
· If blemished due to low-speed machining, increase the cutting speed
· If chattering occurs, decrease the cutting speed · If the depth of cut of the final pass is too small, make it larger
· Tool grade · Select a more wear-resistant grade
· Inappropriate cutting edge inclination angle
· Select the correct shim to ensure relief on the side of the insert
Inappropriate Thread Shape · Tool mounting · Check whether the tool is mounted properly
Shallow Thread Depth· Shallow depth of cut · Check the depth of cut
· Tool wear · Check damage to the cutting edge
Technical Guidance
The Basics of Threading, Turning Edition
N17
References
N
Parts
Technical Guidance Reference
■ Parts
■ Milling Calculation Formulas
Body diameter
Body
Ring
Boss diameter
Bore Dia.
Keyway Width
Keyway Depth
Axial Rake Angle
Chip pocket
Fastener Bolt Face relief angle
Cutting edge indexable Insert
Cutter Diameter (Nominal Diameter)
LocatorClamp Plate
Radial Rake Angle
Reference ring
Face Cutting Edge Angle
Face cutting edge(Wiper Flat)
Chamfered corner
Reference ring
True Rake Angle
Flank Relief Angle
A
Enlarged Portion A
Cutting edgeInclination angle
External cutting edge(Approach Angle)
Cutting edge angle
Cut
ter
heig
ht
External cutting edge (principal cutting edge)
● Calculating power requirements ● Relation between feed rate, work material and specific cutting force
10.000
8.000
6.000
4.000 (1)
(1)
(1)
(2)
(2)
(3)
(3)
(3)(2)2.000
0 0.10.04
0.2 0.4 0.6 0.8 1.0
Feed Rate (mm/t)
Sp
ecifi
c cu
ttin
g fo
rce
(MP
a)
● Horsepower requirements
● Chip evacuation amount
No.
Symbol
Work Material Alloy Steel Carbon Steel Cast Iron Aluminum Alloy(1) 1.8 0.8 200 Q(2) 1.4 0.6 160 Q(3) 1.0 0.4 120 Q
Figures in table indicate these characteristics.· Alloy steel and carbon steel: Traverse rupture strength σ B (GPa)
· Cast iron: Hardness HB
Pc=ae×ap×vf×kc =
Q×kc
60×106×V 60×103×V
H = Pc
0.75
Q = ae × ap × vf
1,000
Pc : Power consumption (kw)
H : Required horsepower (HP)
Q : Chip evacuation amount (cm3/min)
ae : Cutting width (mm)
vf : Feed rate per minute (mm/min)
ap : Depth of cut (mm)
kc : Cutting force (MPa)
Rough values Steel: 2,500 to 3,000MPa
Cast iron: 1,500MPa
Aluminum: 800MPa
V : Machine efficiency (about 0.75)
( )
● Calculating cutting speed
Milling Cutters
Work MaterialDC
n vf
n
vffz
a p
● Calculating feed rate
vc=X×DC×n
1,000
vf =fz × z × n
fz = vf
z×n
vc : Cutting speed (m/min)
X : π ≈3.14
DC : Nominal cutting diameter (mm)
n : Rotation speed (min-1)
vf : Feed rate per minute (mm/min)
fz : Feed rate per tooth (mm/t)
z : Number of teeth
n =1,000×vc
X×DC
Technical Guidance
The Basics of Milling, Milling Edition
N18
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■ Rake angle combination and featuresDouble Positive type Negative - Positive type Double Negative type
Edge combination and chip evacuation
A.R. : Axial rake angleR.R : Radial rake angleA.A. : Approach angle
: Chip and evacuation direction : Cutter rotation direction
A.A. (15 to 30°)A.R. Pos.
R.R. Pos.
A.A. (30 to 45°)A.R. Pos.
R.R. Neg.
A.R.
R.R. Neg.
Neg.
A.A. (15 to 30°)
Advantages Good sharpness Excellent chip evacuation and sharpness
Economical design enabling use of both sides of insert Strong cutting edge
Disadvantages Only single-sided inserts with a lower cutting edge strength can be used
Only single-sided inserts can be used Dull cutting action
ApplicationsMachining of aluminum alloy and other materials requiring sharpness
Machining of steel, cast iron, and stainless steel, with suitable strength and good evacuation
For hard materials such as cast iron or poor surfaces such as castings
Cat. No. ANX Type, WEZ Type, HF Type, WAX Type WGX Type, WFX Type, RSX Type, MSX Type TSX Type, DGC Type, DFC Type, DNX Type
Chips (Ex.)
· Work material: SCM435· vc =130m/min
fz =0.23mm/t ap=3mm
■ Functions of cutting edge anglesMaterial Symbol Function Effect
(1) (2)
Axial rake angle Radial rake angle
A.R. R.R.
Determines chip evacuation direction, adhesion, thrust, etc.
Available in positive to negative (large to small) rake angles. Typical combinations: Positive and Negative, Positive and Positive, Negative and Negative
(3) Approach angle A.A. Determines chip thickness and chip evacuation direction
Large: Thin chips Small cutting force
(4) True rake angle T.A. Effective rake angle Positive (Large): Excellent machinability and low chip adhesion. Low cutting edge strength
Negative (Small): Strong cutting edge and easy chip adhesion
(5) Cutting edge inclination angle I .A. Determines chip control direction Positive (Large): Excellent chip control and small cutting force. Low cutting edge strength
(6) Face cutting edge angle F.A. Determines surface finish roughness Small: Excellent surface roughness
(7) Relief angle Determines cutting edge strength, tool life, chattering
True rake angle (T.A.) table
+30°
0° 5° 10° 15° 20° 25° 30° 35°
+25°+20°+15°+10°
+5°0°
-5°-10°-15°-20°-25°-30°
+30°+25°+20°+15°+10°
+5°0°
-5°-10°-15°-20°-25°-30°
+30°+25°+20°+15°+10°
+5°0°
-5°
-20°-25°
-10°-15°
45°50°55° 60° 65° 70° 75° 80° 85° 90°40°
Rad
ial r
ake
angl
e R
.R.
Axi
al r
ake
angl
e A
.R.
Approach angle A.A.
True rake angle T.A.
-30°
(2)
(1)
(3)
(4)
Formula: tan T.A.=tan R.R./cos A.A. + tan A.R./sin A.A.
Example: (1) A.R.(2) R.R.(3) A.A.
(Axial rake angle)(Radial rake angle) (Approach angle)
= +10°= -30°= 60°}-> (4)
T.A. (True rake angle) = -8°
Inclination angle (I.A.) chart
-30°
0° 5° 10° 15° 20° 25° 30° 35°
-25°-20°-15°-10°-5°0°
+5°+10°+15°+20°+25°+30°
+30°+25°+20°+15°+10°+5°
0°-5°
-10°-15°-20°-25°-30°
-30°-25°
-10°-5°0°
+5°
+20°+25°
+10°+15°
45°50°55° 60° 65° 70° 75° 80° 85° 90°40°
Axi
al r
ake
angl
e A
.R.
Rad
ial r
ake
angl
e R
.R.
Approach angle A.A.
Inclination angle I.A.
+30°
-20°-15°1
(3)
(4)
(2)
Formula: tan I.R.=tan A.R./cos A.A. - tan R.R./sin A.A.
Example: (1) A.R.(2) R.R.(3) A.A.
(Axial rake angle)(Radial rake angle)(Approach angle)
= -10°= +15°= 25°}-> (4)
I (inclination angle) = -15°
Technical Guidance
The Basics of Milling, Milling Edition
N19
References
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Technical Guidance Reference
● Surface roughness without wiper flat ● Surface roughness with wiper edge (difference in face cutting edge)
HC
· Work material: SCM435
· Cutter: DPG5160R
(per tooth)
· vc = 154m/min
fz = 0.234mm/t
ap = 2mm
· Face Cutting Edge Angle
(A): 28’
(B): 6’
● Surface roughness with straight wiper flat
HF
h: Projection value of wiper insertCast Iron: 0.05mmAl: 0.03mm
HW
Wiper Insert
NormalEdge Type
h
● Effects of wiper insert (example)
· Work material: FC250
· Cutter: DPG4100R
· Insert: SPCH42R
· Face runout: 0.015mm
· Runout: 0.04mm
vc = 105m/min
fz = 0.29mm/t
(1.45mm/rev)
(C): Normal teeth
(D): Per wiper edge
f: Feed rate per revolution (mm/rev)
HC
f f
HW
Hc: Surface roughness with only normal teethHw: Surface roughness with wiper insert
( )
■ Relation between engagement angle and tool life
Work material feed direction (Vf)
Cut
ting
Wid
th (W
)
n
Milling CuttersRotationdirection
InsertEngagement
Angle (E)
DC
The engagement angle denotes the angle at which the full length of the cutting edge comes in contact with the work material, with reference to the feed direction.· The larger E is, the shorter the tool life
· To change the value of E: (1) Increase the cutter size (2) Shift the position of the cutter
Rel
atio
n to
cut
ter
dia
met
er
Large diameter
vf
ESmall E
n
DC
Small diameter
vf
ELarge E
n
DC
Rel
atio
n to
cut
ter
pos
ition
vf
n
E
Small E E
vf
n
Large E
Rel
atio
n to
too
l life
Tool
Life
(mill
ing
area
) (m
2 )
0.4
-30° 0° 30° 60°
0.3
0.2
0.1
S50C
Engagement Angle Tool
Life
(mill
ing
area
) (m
2 )
-20° 0° 40° 60° 80°20°
0.6
0.4
0.2
FC250
Engagement Angle
■ Improving surface roughness
(1) Inserts with wiper flatWhen all of the cutting edges have wiper flats, a few teeth protrude due to inevitable runout and act as wiper inserts.· Insert equipped with straight wiper flat (Face angle: Around 15' to1°)
· Insert equipped with curved wiper flat (Curvature: ≈ R500 (example))
(2) Wiper insert assembling systemA system in which one or two inserts (wiper inserts) protrude with a smooth curved edge just a little beyond the other teeth to wipe the milled surface. (Applicable to WGX Type, DGC Type, etc.)
● Relation between the number of simultaneously engaged cutting edges and cutting force
· 0 or 1 edge in contact at same time
· Only 1 edge in contact at any time
· 1 or 2 edges in contact
· 2 edges in contact at any time
· 2 to 3 edges in contact
a) b) c) d) e)
Time
Cuttin
g forc
e
Time
Cuttin
g forc
e
Time
Cuttin
g forc
e
Time
Cuttin
g forc
e
Time
Cuttin
g forc
e
Wor
k M
ater
ial
Milling Cutters
Normally, a cutting width 70 to 80% of the cutter diameter is considered appropriate, as shown in example d). However, this may not apply due to the actual rigidity of the machine or workpiece, and the machine horsepower.
(C)
(Only normal teeth)
Roug
hnes
s (μ m
)
×1,000
Feed per revolution
2020
15
10
5
(D)
(Wiper edgeWith 1 wiper insert)
Roug
hnes
s (μ
m)
×1,000
2020
15
10
5
(A)
Feed rateper tooth
Feed rateper tooth
(B)
Feed rate per tooth Feed rate per tooth
×2,000
×100
Technical Guidance
The Basics of Milling, Milling Edition
N20
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Failure Basic Remedies Countermeasure Examples
Cut
ting
Ed
ge D
amag
e
Excessive Flank Wear Tool Grade
Cutting
Conditions
· Select a more wear-resistant grade
Carbide P30 → P20
→ Coated
K20 → K10 Cermet
· Decrease the cutting speed
· Increase feed rate
· Recommended Insert Grade
Excessive Crater Wear Tool Grade
Tool Design Cutting
Conditions
· Select a crater-resistant grade · Use a sharp chipbreaker (G → L)· Decrease the cutting speed · Reduce depth of cut and feed rate
· Recommended Insert Grade
Chipping Tool Grade
Tool Design
Cutting Conditions
· Use a tougher grade P10 → P20 → P30 K01 → K10 → K20
· Select a negative/positive cutter with a large peripheral cutting edge angle (a small approach angle).
· Reinforce the cutting edge (honing)· Change chipbreaker (G → H)· Reduce feed rate
· Recommended Insert Grade
· Recommended cutter: SEC-WaveMill WGX Type · Cutting conditions: Refer to H20
Breakage Tool Grade
Tool Design
Cutting Conditions
· If it is due to excessive low speeds or very low feed rates, select a grade resistant to chip adhesion
· If the cause is thermal cracking, select a thermal impact resistant grade
· Select a negative/positive (or double negative) cutter type with a large peripheral cutting edge angle (a small approach angle)
· Reinforce the cutting edge (honing)· Change chipbreaker (G → H)· Increase insert size (thickness in particular)
· Select appropriate conditions for that particular application
· Recommended Insert Grade
· Recommended cutter: SEC-WaveMill WGX Type
· Insert thickness: 3.18 → 4.76mm
· Change chipbreaker: Standard → Strong edge type
· Cutting conditions: Refer to H20
Oth
ers
Unsatisfactory Machined Surface Finish
Tool Grade
Tool Design
Cutting Conditions
· Select an adhesion-resistant grade Carbide → Cermet · Improve axial runout of cutting edges
Use a cutter with less runout Mount the correct insert · Use a wiper insert · Use cutters dedicated for finishing · Increase the cutting speed
· Recommended Cutters and Insert Grades
Cutters marked with * can be mounted with wiper inserts.
Chattering Tool Design
Cutting ConditionsOthers
· Select a cutter with sharp cutting edges· Use an irregular pitched cutter · Reduce the feed rate · Improve the rigidity of the workpiece and cutter clamp
· Recommended cutter For steel: SEC-WaveMill WGX Type For cast iron: SEC-Sumi Dual Mill DGC Type For light alloy: Aluminum Body Cutter RF Type
Unsatisfactory Chip Control
Tool Design
· Select a cutter with good chip evacuation features
· Reduce number of teeth · Enlarge chip pocket
· Recommended cutter: SEC-WaveMill WGX Type
Edge Chipping On Workpiece
Tool Design
Cutting Conditions
· Increase the peripheral cutting edge angle (decrease the approach angle)
· Change chipbreaker (G → L)· Reduce the feed rate
· Recommended cutter: SEC-WaveMill WGX Type
Burr formation Tool Design Cutting
Conditions
· Use a sharp cutter · Increase feed rate · Use a burr-proof insert
· Recommended cutter: SEC-WaveMill WGX Type + FG Chipbreaker SEC-Sumi Dual Mill DGC Type + FG Chipbreaker
Steel Cast Iron Non-Ferrous Alloy
Finishing T250A, T4500A (Cermet)
ACK100 (Coated) BN7000 (SUMIBORON) DA1000 (SUMIDIA)
Roughing ACP100 (Coated) ACK200 (Coated) DL1000 (Coated)
Steel Cast Iron
Roughing ACP300 (Coated) ACK300 (Coated)
Steel Cast Iron
Finishing ACP200 (Coated) ACK200 (Coated)
Roughing ACP300 (Coated) ACK300 (Coated)
Steel Cast Iron Non-Ferrous Alloy
General
-purpo
se
Cutter Insert
WGX Type* ACP200 (Coated)
DGC Type ACK200 (Coated)
RF type * H1 (Carbide)
DL1000 (Coated Carbide)
Finish
ing Cutter Insert
WGX Type T4500A (Cermet)
FMU Type BN7000
(SUMIBORON)
RF Type DA1000
(SUMIDIA)
Steel Cast Iron Non-Ferrous Alloy
Finishing T250A, T4500A (Cermet) ACK100 (Coated) DA1000 (SUMIDIA)
Roughing ACP100 (Coated) ACK200 (Coated) DL1000 (Coated)
( )
( ) {
■ Troubleshooting for Milling
Technical Guidance
Troubleshooting for Milling, Milling Edition
N21
References
N
Parts
Technical Guidance Reference
■ Parts
■ Calculating cutting conditions (square endmill)
(Ballnose Endmill)
O.D.
Body
Cutter sweep
NeckHead Diameter
Shank
Shank Dia.
Shank length
Neck length
Cutting Edge Length
Overall Length
Centre hole
Land width
Flank width Radial flankRadial primary relief angle
Radial secondary relief angle
Axial primary relief angle
Ballnose Radius
Axial secondary relief angle
Concavity angle of end cutting edge (*)
Margin widthMargin
LandLand width
Centre Cut With Centre Hole
Rake Face Rake Angle
Groove
Flute depth Chip pocket
Helix Angle
Peripheral Blade
End cutting edge
Corner
End gash
Rounded flute bottomCentre hole
Heel
Web thickness
* Centre area is lower than the periphery
● Calculating cutting speed
vc : Cutting speed (m/min) X : π ≈3.14DC : Endmill diameter (mm)n : Spindle speed (min-1)vf : Feed rate (mm/min)f : Feed rate per revolution
(mm/rev)fz : Feed rate per tooth (mm/t)z : Number of teethap : Depth of cut in axial
direction (mm)ae : Depth of cut in radial
direction (mm)RE : Ballnose radius
vc =X×DC×n
1,000n =
1,000×vc
X×DC
● Calculating feed rate per revolution and per tooth
vf = n×f f =vf n
fz =f
=vf
z n×zvf = n×fz×z
● Calculating notch width (D1)
D1=2× 2×RE×ap - ap2
● Cutting speed and feed rate (per revolution and per tooth) are calculated using the same formula as the square endmill.
ap
ae
DC
ap
DC
ap Depth of cut
D1
RE
pf Pick feed
ap
DC
D1
pf
RE
Side Milling Groove Milling
Technical Guidance
The Basics of Endmilling, Endmilling Edition
N22
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■ Up-cut and Down-cut
■ Relation between cutting conditions and deflection
Endmill
specifications
Side Milling Grooving
Work Material: Pre-hardened
steel (40HRC)
Cutting Conditions: vc=25m/min
ap=12mm ae=0.8mm
Work Material: Pre-hardened
steel (40HRC)
Cutting Conditions: vc=25m/min
ap=8mm ae=8mm
Cat.
No.
Number
of Teeth
Helix
Angle
Feed Rate Feed Rate Feed Rate Feed Rate
0.16mm/rev 0.11mm/rev 0.05mm/rev 0.03mm/rev
Style Style Style Style
Up-cut Down-cut Up-cut Down-cut Up-cut Down-cut Up-cut Down-cut
2 30°
4 30°
Results· The tool tip tends to back off with the down-cut.
· The 4-flute type offers more rigidity and less backing off.
· The side of the slot tends to cut into the up-cut side toward the bottom of the slot.
· The 4-flute type offers higher rigidity and less deflection.
● Side Milling ● Slotting
● Cutting Edge Wear Amount ● Surface Roughness ● Cutting Conditions
Work material: S50CTool: GSX21000C-2D
(ø10mm, 2 teeth)
fz fz
Work Material Feed Direction
Work Material
(a) Up-cut
Work Material Feed Direction
Work Material
(b) Down-cut
fz
Work Material Feed Direction
Work Material
Up-cut side
Down-cut side
(a) Up-cut (b) Down-cut
Work Material Feed Direction Work Material Feed Direction
Work Material Work Material
Flan
k W
ear
Wid
th (m
m)
50 100 150 200 2500
0.010.020.030.040.050.060.070.08
Cutting Length (m)
Up-cut
Down-cut
5
4
3
2
1
0
Up-cut
Down-cut
Rz
(μm
)
Up-cut
Down-cut
Feed Direction Roughness Vertical Direction Roughness
Machined surface
Reference surface
UpCut side
DownCut side
GS
X20
800S
-2D
GS
X40
800S
-2D
Technical Guidance
The Basics of Endmilling, Endmilling Edition
Cutting conditions: vc=88m/min
(n=2800min-1)vf=560mm/min(fz=0.1mm/t)ap=15mm ae=0.5mm Side milling Dry, air
N23
References
N
Parts
Technical Guidance Reference
■ Troubleshooting for Endmilling
Failure Cause Countermeasures
Cut
ting
Ed
ge F
ailu
re
Excessive Wear · Cutting Conditions
· Cutting speed is too fast· Decrease cutting speed and feed rate
· Feed rate is too large
· Tool Shape · The flank relief angle is too small · Change to an appropriate flank relief angle
· Tool Material · Insufficient wear resistance· Select a more wear-resistant substrate· Use a coated tool
Chipping · Cutting Conditions
· Feed rate is too large · Decrease cutting speed
· Depth of cut is too large · Reduce depth of cut
· Tool overhang is too long · Adjust tool overhang to the correct length
· Machine Area
· Workpiece clamping is too weak · Clamp the workpiece firmly
· Tool mounting is unstable · Make sure the tool is seated in the chuck properly
Fracture· Cutting Conditions
· Feed rate is too large · Decrease cutting speed
· Depth of cut is too large · Reduce depth of cut
· Tool overhang is too long · Reduce tool overhang as much as possible
· Cutting edge is too long · Select a tool with a shorter cutting edge
· Tool Shape · Web thickness is too small · Change to more appropriate web thickness
Oth
ers
Deflection in Wall Surface· Cutting Conditions
· Feed rate is too large · Decrease cutting speed
· Depth of cut is too large · Reduce depth of cut
· Tool overhang is too long · Adjust tool overhang to the correct length
· Cutting on the down-cut · Change direction to up-cut
· Tool Shape· Helix angle is too large · Use a tool with a smaller helix angle
· Web thickness is too small · Use a tool with the appropriate web thickness
Unsatisfactory Machined Surface Finish
· Cutting Conditions
· Feed rate is too large · Decrease cutting speed
· Biting of chips· Use air blow
· Use an insert with a larger relief pocket
Chattering · Cutting Conditions
· Cutting speed is too fast · Decrease the cutting speed
· Cutting on the up-cut · Change direction to down-cut
· Tool overhang is too long · Adjust tool overhang to the correct length
· Tool Shape · Rake angle is too large · Use a tool with an appropriate rake angle
· Machine Area
· Workpiece clamps are too weak · Clamp the workpiece firmly
· Tool mounting is unstable · Make sure the tool is seated in the chuck properly
Chip Blockage · Cutting Conditions
· Feed rate is too large · Decrease cutting speed
· Depth of cut is too large · Reduce depth of cut
· Tool Shape· Too many teeth · Reduce number of teeth
· Biting of chips · Use air blow
Technical Guidance
Troubleshooting for Endmilling, Endmilling Edition
N24
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ce
Margin width
Margin
Body clearance
FluteFl
ute
Wid
thLand widthChisel edge angle
Cutting edge
Chisel edge corner
Chisel edge
Depth of body clearance
Relief Angle Rake
Ang
leDiameter of body clearance
Web thinning
Chisel edge length
Flank
Height of point
Bla
de
Dia
.
Cutting edge
Outer corner
Heel
Leading edge
Back Taper
Lead
Body clearance
Rake Face
Helix AnglePoint anglePoint angle
Flute Length
Shank Length
Taper shank
Overall Length
Neck
Sha
nk D
ia.
A
A:B or A/B = Groove width ratio
B
■ Parts of Drill
● Point angle and force● Minimum requirement relief
angle for drilling● Relation between edge
treatment and cutting force
● Point angle and burr● Effects of web thinning
● Chisel width decreased by thinning
T
Md
Point angle (small)
T
Md
Point angle (large)
X·DC
DC
XDX
DX
Pθx
f: Feed rate (mm/rev)
f
Thru
st (N
)
0.2 0.3 0.40
2,000
4,000
6,000
8,000
Feed Rate (mm/rev)
Torq
ue (N·m
)
0.2 0.3 0.40
20
40
60
Feed Rate (mm/rev)
Thru
st
Thru
st
Removed
S Type N Type X Type
When point angle is large, thrust increases but torque decreases.
When point angle is large, burr height becomes low.
Work material: SS41Cutting speed: vc=50m/min
Bur
r he
ight
(mm
)
0.05 0.10 0.15
118°
140°
150°
0.20 0.250
0.2
0.4
0.6
0.8
Feed Rate (mm/rev)
Web thinning decreases the thrust concentrated at the chisel edge, makes the drill edge sharp, and improves chip control.
Px=tan-1f
π · DX* A large relief angle is needed
at the centre of the drill.
Typical types of thinning
S Type: Standard type used for general purposes.N Type: Suitable for thin web drills.X Type: For hard-to-cut materials or deep hole drilling.
Entry easier.
Drill : MultiDrill KDS215MAKEdge treatment width : ●→ 0.15mm
△→ 0.23mmWork material : S50C (230HB)Cutting conditions : vc=50m/min, wet
Technical Guidance
Basics of Drilling, Drilling Edition
N25
References
N
Parts
Technical Guidance Reference
■ Reference of Power Requirements and Thrust
■ Cutting Condition Selection● Control cutting force
for low-rigidity machines
● High speed machining recommendation
f: Feed rate (mm/rev)
Work material: S48C (220HB)
The following table shows the relation between edge treatment width and cutting force. If the cutting force is too great and causes issues, take measures such as reducing the feed rate or reducing the cutting edge treatment of the drill.
Cutting ConditionsEdge treatment width
0.15mm 0.05mm
vc(m/min) f (mm/rev) Torque (N/m) Thrust (N) Torque (N/m) Thrust (N)
40 0.38 12.8 2,820 12.0 2,520
50 0.30 10.8 2,520 9.4 1,920
60 0.25 9.2 2,320 7.6 1,640
60 0.15 6.4 1,640 5.2 1,100
If the machine has enough power and sufficient rigidity, reasonable tool life can be ensured even when adopting higher efficiency machining; however, sufficient coolant must be supplied.
Drill Diameter : ø10mmWork material : S50C
(230HB)
Work material : S50C (230HB)Cutting conditions : f = 0.3mm/rev
H=50mmTool life : 600 holes (Cutting length: 30m)
Mar
gin
↑↓
Flan
k
↓
Rak
e Fa
ce
Pow
er c
onsu
mp
tion
(kW
)10 20 30 40
0
2
4
6
8
Drill diameter (DC) (mm)
f=0. 3
f=0. 2
f=0. 1 Thru
st (N
)
10 20 30 400
12,000
10,000
8,000
6,000
4,000
2,000
Drill diameter (DC) (mm)
f=0. 3
f=0. 2
f=0. 1
Wear example
vc=60m/min vc=120m/min
■ Explanation of Margins (Difference between single and double margins)
● Single Margin (2 guides: ○ part) ● Double Margin (4 guides: ○ part)
● Shape used on most drills ● 4-point guiding reduces hole bending and undulation for improved stability and accuracy during deep hole drilling.
Technical Guidance
Basics of Drilling, Drilling Edition
N26
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Chu
ck0.03mm
(A)
(B)
■ Runout Accuracy
■ Drill Mounting Peripheral Runout Accuracy
■ Work Material Surface and Drill Performance
■ How to Use a Long Drill
For the runout accuracy of web-thinned drills, the runout after thinning (A) is important in addition to the difference in lip height (B).
● When the tool rotatesThe peripheral runout accuracy of the drill mounted on the spindle should be controlled within 0.03mm. If the runout exceeds the limit, the drilled hole will also become large and an increase in the horizontal cutting force, which may result in drill breakage.
● When the work material rotatesThe peripheral runout at the drill edge (A) and the concentricity at (B) should be controlled within 0.03mm.
● Work material with slanted or uneven surfaceIf the surface of the hole entrance or exit is slanted or uneven, decrease the feed rate to 1/3 to 1/2 of the recommended cutting conditions.
● ProblemWhen using a long drill (e.g. XHGS Type), SMDH-D Type drill or SMDH-12.5D Type drill at high rotation speeds, the runout of the drill tip may cause a deviation of the entry point as shown on the right, bending the drill hole and resulting in drill breakage.
● Remedies
(A): Runout accuracy of thinning point(B): The difference of the lip height
0
0. 05
0. 10
0. 15
0. 20
0. 25
0. 005 0. 02 0.05
0.050.005 0.02 0.020.1 0.1
0.1
MDS140MKS50Cvc = 50m/min f = 0.3 mm/rev
Centre runout
Peripheral runout
Hol
e ex
pans
ion
(mm
)
(Unit: mm)
(A) (mm)
(B) (mm)
(A)
(B)
0 0.05 (mm) 0 10 (kg)
Peripheral runout(mm)
* Horizontal cutting force.
Drill: MDS120MK, work material: S50C (230HB)
Cutting Conditions: vc=50m/min, f = 0. 3mm/rev, H = 38mm
Water-soluble Coolant
0. 005
0.09
Hole expansion Cutting Force*
Runout: Within 0.03mm
Runout: Within 0.03mm
(Entrance) (Exit)
Hole bend
Position shift
Method 1
Step 1 Step 2
Drilling under recommended conditions
2 to 3mm
(n=100 to 300min-1) f=0.15 to 0.2mm/rev
Method 2 *Low rotational speed minimises centrifugal forces and prevents the drill from bending.
Step 1 Step 2
Short drill
1xDC prepared hole machining (same diameter)
2 to 3mmn=100 to 300min-1
Step 3
Drilling under recommended conditions
Technical Guidance
Basics of Drilling, Drilling Edition
N27
References
N
Parts
Technical Guidance Reference
■ Drill Regrinding
1 to 2 feed marks
Excessive marks
● Tool life determinant
Appropriate Tool Life
Over-used
● When to regrindWhen one or two feed marks (lines) appear on the margin, when corner wear reaches the margin width or when small chipping occurs, it indicates that the drill needs to be sent for regrinding.
● How and where to regrindWe recommend regrinding and recoating. Regrinding alone may be sufficient, but if the work material is steel, use recoating as well as regrinding to prevent shortening of tool life. Note: Ask us or an approved vendor to recoat with our proprietary coating.
● Regrinding on your ownCustomers regrinding their own drills can obtain MultiDrill Regrinding Instructions from us directly or their vendor.
Use high pressure at entrance
Easy to use
Use high pressure at entrance
● Vertical drilling
● Horizontal drilling
■ Drill Maintenance ■ Using Cutting Oil
■ Calculation of Power Consumption and Thrust ■ Clamping of the Workpiece
(1) Collet Selection and Maintenance
●Ensure proper chucking of drills to prevent vibration. Collet type chucks are recommended, as the grip is strong and can be used with ease.
●When replacing drills, regularly remove cutting chips inside the collet by cleaning the collet and the spindle with oil. Repair marks with an oilstone.
(2) Drill Mounting●The peripheral runout of the
drill mounted on the spindle must be within 0.03mm.
●Do not chuck on the drill flute.
(1) Choosing Cutting Oil●If the cutting speed is more than
40m/min, cutting oil (JISW1 type 2) is recommended as its cooling effects and chip control capacity are good, and it is highly soluble.
●For optimum tool life at cutting speeds of less than 40m/min, sulfo-chlorinated oil (JISA1 type 1) is recommended as it has a lubricating effect and is non-water soluble. * Insoluble cutting oil may be flammable. To prevent fire, a substantial amount of oil should be used to cool the component so that smoke and heat will not be generated.
(2) Supply of Coolant●External Coolant Supply
There must be a sufficient external supply of coolant at the hole position. Coolant pressure 0.3 to 0.5MPa, coolant volume 3 to 10M/min is a guideline.
●Internal Coolant SupplyFor holes ø4 or smaller, the oil pressure must be at least 1.5MPa to ensure a sufficient supply of coolant. For ø6 and above, if L/D is <3, the pressures should be at 0.5 to 1.0MPa. If L/D is >3, a hydraulic pressure of at least 1 to 2MPa is recommended.
High thrust forces occur during high-efficiency drilling. Therefore, the workpiece must be supported to prevent fractures caused by deformation. Large torques and horizontal cutting forces also occur. Therefore, the workpiece must be clamped firmly enough to withstand them.
If the drill flute is inside the holder, chip evacuation will be obstructed, causing damage to the drill.
( )
( )
Collet Chuck
Collet
If there are marks, repair with an oilstone or change to a new one
Peripheral runout within 0.03mm
Do not grip on the drill flute
Collet
Drill Chuck
● External Coolant Supply
● Internal Coolant Supply
● Coolant supply equipment
● Internal supply from machine
Deformation → chipping Support needed
Especially large drills
* When designing the machine, an allowance of 1.6 x power consumption and 1.4 x thrust should be given.
Power consumption (kW) = HB×DC0.68×vc1.27×f 0.59/36,000
Thrust (N)=0.24×HB×DC0.95×f 0.61×9.8
Drill chucks and keyless chucks are not suitable for MultiDrills as they have a weaker grip force.
● Calculating cutting speed
vc =X×DC×n
1,000
n =1,000×vc
X×DC
● Calculating feed rate per revolution and per tooth
vf = n×f f =vf n
T =Hvf
● Calculation of Cutting Time
● Calculation of Power Consumption and Thrust <Experimental>
vc : Cutting speed (m/min)
X : π ≈3.14DC : Drill diameter (mm)n : Rotation speed (min-1)vf : Feed rate (mm/min)f : Feed rate per revolution
(mm/rev)H : Drilling depth (mm)T : Cutting time (min)HB : Work material Brinell
hardness
Hol
e D
epthn
DC
H
Technical Guidance
MultiDrill Usage Guidance, Drilling Edition
N28
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■ Troubleshooting for Drilling
Failure Cause Basic Remedies Countermeasure Examples
Dril
l Fai
lure
Excessive Wear on Rake Face
· Inappropriate cutting conditions
· Use higher cutting speeds · Refer to the upper limit of the recommended cutting conditions listed in the IGETALLOY Cutting Tools Catalogue
· Increase feed rate · Refer to the upper limit of the recommended cutting conditions listed in the IGETALLOY Cutting Tools Catalogue
· Unsuitable coolant· Reduce pressure if using internal coolant · 1.5MPa or less (external coolant supply can be used at hole depths (L/D) of 2 or less)
· Use coolant with more lubricity · Use JIS A1 grade No.1 or its equivalent
Chisel Point Breakage
· Off-centre starts· Reduce feed rate at entry point · f=0.08 to 0.12mm/rev
· Pre-machining of flat surface for entry · Drill flat base with Flat MultiDrill
· Equipment, work materials, etc. lack rigidity
· Change cutting conditions to reduce resistance · Increase vc to decrease f (reduce thrust)
· Improve clamp strength of work material
· Cutting edge is too weak
· Increase size of chisel width · Use a chisel with a width of 0.1 to 0.2mm
· Increase amount of honing on cutting edge · Increase the width of the thinning area at the centre by 1.5 times
Breakage on Peripheral Cutting Edge
· Inappropriate cutting conditions
· Decrease the cutting speed · Refer to the lower limit of the recommended cutting conditions listed in the IGETALLOY Cutting Tools Catalogue
· Reduce feed rate · Refer to the lower limit of the recommended cutting conditions listed in the IGETALLOY Cutting Tools Catalogue
· Unsuitable coolant · Use coolant with more lubricity · Use JIS A1 grade No.1 or its equivalent
· Equipment, work materials, etc. lack rigidity · Improve clamp strength of work material
· Cutting edge is too weak
· Increase amount of honing on cutting edge · Increase the width of the outer cutting edge by 1.5 times
· Reduce the front relief angle · Reduce the front relief angle by 2 to 3°
· Entry from peripheral cutting edge · Increase margin width (W margin specification) · Increase the margin width by 2 to 3 times
· Interrupted through cutting
· Reduce feed rate · Refer to the lower limit of the recommended cutting conditions listed in the IGETALLOY Cutting Tools Catalogue
· Increase amount of honing on cutting edge · Increase the width of the outer cutting edge by 1.5 times
· Reduce the front relief angle · Reduce the front relief angle by 2 to 3°
Margin Wear · Inappropriate cutting conditions · Decrease the cutting speed · Refer to the lower limit of the recommended cutting conditions listed in the IGETALLOY Cutting Tools Catalogue
· Unsuitable coolant· Use coolant with more lubricity · Use JIS A1 grade No.1 or its equivalent
· Use more coolant · If using external coolant, switch to internal coolant
· Remaining margin wear · Schedule for earlier regrind and ensure back taper · If margin damage occurs, regrind to 1mm or less
· Improper tool design· Increase amount of back taper · Make back taper 0.5/100
· Reduce margin width · Reduce the margin width to around 2/3
Drill Breakage · Chip blockage· Use the optimal cutting conditions and tools · Refer to recommended cutting conditions listed in the IGETALLOY Cutting Tools Catalogue
· Use more coolant · If using external coolant, switch to internal coolant
· Holding clamp too weak
· Use strong holding clamp· If the collet chuck is damaged, replace it· Change the collet holder to the next size up
· Equipment, work materials, etc. lack rigidity · Improve clamp strength of work material
Uns
atis
fact
ory
Hol
e A
ccur
acy
Oversized Holes· Off-centre starts
· Reduce feed rate at entry point · f=0.08 to 0.12mm/rev
· Decrease the cutting speed · Refer to the lower limit of the recommended cutting conditions listed in the IGETALLOY Cutting Tools Catalogue
· Pre-machining added for entry in planar surfaces · Planar machining with endmill
· Drill bit lacks rigidity· Use the optimal drill type for the hole depth · Refer to the IGETALLOY Cutting Tools Catalogue
· Improve overall drill rigidity · Large web, small groove width
· Drill bit has runout· Improve drill mounting precision · If the collet chuck is damaged, replace it
· Improve drill retention rigidity · Change the collet holder to the next size up
· Equipment, work materials, etc. lack rigidity · Improve clamp strength of work material
Poor Surface Roughness
· Inappropriate cutting conditions
· Increase the cutting speed · Refer to the upper limit of the recommended cutting conditions listed in the IGETALLOY Cutting Tools Catalogue
· Reduce feed rate · Refer to the lower limit of the recommended cutting conditions listed in the IGETALLOY Cutting Tools Catalogue
· Unsuitable coolant · Use coolant with more lubricity · Use JIS A1 grade No.1 or its equivalent
Holes are not straight
· Off-centre starts · Increase feed rate · Refer to the upper limit of the recommended cutting conditions listed in the IGETALLOY Cutting Tools Catalogue
· Drill is not mounted properly
· Improve drill mounting precision · If the collet chuck is damaged, replace it
· Improve drill retention rigidity · Change the collet holder to the next size up
· Equipment, work materials, etc. lack rigidity
· Improve clamp strength of work material
· Select a double margin tool · Refer to the IGETALLOY Cutting Tools Catalogue
Uns
atis
fact
ory
Chi
p C
ontr
ol
Chips clog · Inappropriate cutting conditions
· Increase cutting speeds · Refer to the upper limit of the recommended cutting conditions listed in the IGETALLOY Cutting Tools Catalogue
· Increase feed rate · Refer to the upper limit of the recommended cutting conditions listed in the IGETALLOY Cutting Tools Catalogue
· Poor chip evacuation · Increase volume if using internal coolant
Long Stringy Chips · Inappropriate cutting conditions
· Increase feed rate · Refer to the upper limit of the recommended cutting conditions listed in the IGETALLOY Cutting Tools Catalogue
· Increase cutting speeds · Refer to the upper limit of the recommended cutting conditions listed in the IGETALLOY Cutting Tools Catalogue
· Strong cooling effect · Reduce pressure if using internal coolant · The pressure should be 0.5 MPa or less if using internal coolant
· Dull cutting edge · Reduce amount of edge honing · Reduce the width to around 2/3
Technical Guidance
Troubleshooting for Drilling, Drilling Edition
N29
References
N
Parts
Technical Guidance Reference
■ Recommended Zones for SUMIBORON by Workpiece Hardness and Shape
■ Cutting speed recommendations for each work material
300
100
200
Cut
ting
Sp
eed
(m/m
in)
Carburised or induction hardened material Bearing Steel Die Steel
Prone to notch wear
Fairly large amount of wear
Large amount of wear
■ Influence of coolant on tool life
20
0.3
0.25
0.2
0.15
0.1
0.05
040 60 80 100 120 140
Cutting Time (min)
Flan
k W
ear
Wid
th (V
B) (
mm
)
DryOil-based coolantWater soluble emulsionWater soluble
☆ In continuous cutting of bearing steel, there is not much difference between dry and wet cutting.
Dry
Interrupted Cutting
0
50
100
Heavy
Wet cut
Tool
Life
■ Relation between work material hardness and cutting force
■ Relation between flank wear and cutting force
0.05
300
200
100
0
100
0100
00.10
Flank Wear Width (VB) (mm)
Bac
k fo
rce
(N)
Prin
cipa
l For
ce (N
)Fe
ed fo
rce
(N)
SCM43065HRC
S55C24HRC
■ Influence of work material hardness on cutting force and accuracy
Back
forc
e (N)
Dim
ensio
ns (μ
m)
Shor
e har
dnes
s (HS
)
Hard zone
Hard zone
Soft zone
Work material: S38C
45(HS)
106N
90
70
50
30
400
300
200
13μm0
-10
-20
■ Improvement of surface roughness by altering the feed rateConstant Feed Rate Variable Feed Rate
f
Stationary Notch Location
Previous Edge Position f
Shifting Notch Location
☆ Varying the feed rate spreads the notch location over a larger area.→ Surface finish improves and notch wear decreases.
■ Relation between cutting speed and surface roughness
400 80 120 1600
0.1
0.2
0.3
Machining Output (pcs.)
Sur
face
Rou
ghne
ss (R
a) (μ
m) BN250 Vc=120
BN250 Vc=150BN250 Vc=180
Work material : SCM420H 58 to 62HRC
Holder : MTXNR2525Tool : NU-TNMA160408
Cutting Conditions:
vc =120,150,180m/minf = 0.045mm/revap = 0.15mm
Wet
At high cutting speeds, surface roughness is more stable.
Feed Force
Principal Force
Back Force
10
150
100
50
030 50 70
Cut
ting
forc
e (N
)
Principal ForceFeed ForceBack Force
Hardness of Work Material (HRC)
Cutting conditions: Cutting speed (vc) = 80 m/min Depth of cut (ap) = 0.15mm Feed rate (f ) =0.1mm/rev
For hardened steel machining, back force increases substantially due to the expansion of flank wear.
External dimensions in the soft zone are smaller due to lower cutting forces.
Work material: SUJ2(58 to 62 HRC)Cutting conditions: TPGN160304vc=100m/min, ap=0. 15mm, f=0. 1mm/rev Continuous Cutting
For continuous cutting, the influence of coolant on tool life is minimal.For interrupted cutting, the thermal impact shortens the tool life in wet conditions.
Back force increases substantially for harder workpieces.
Work Material:Cutting Conditions:
40 45 50 55 60 65Hardness of work material (HRC)
Heavy
Light
Inte
rrup
ted
Cut
ting
Cont
inuo
us C
uttin
g
Coated carbide Cermet SUMIBORON
Ceramic
Milling of SKD11 to 4 U groovesCutting speed: vc=100m/minDepth of cut: ap= 0.2 mmFeed rate (f )=0.1 mm/rev
● Continuous Cutting ● Interrupted Cutting
SK3Cutting speed (vc) =120m/min, depth of cut (ap) = 0.2mmFeed rate (f ) =0.1 mm/rev
Cutting Speed :Depth of Cut :Feed Rate :
vc = 120m/minap = 0.5mmf = 0.3mm/rev, dry
Technical Guidance
Hardened Steel Machining with SUMIBORON, SUMIBORON Edition
N30
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■ Advantages of using SUMIBORON for cast iron machining
■ Milling
● Higher accuracy ● Longer tool life at higher cutting speeds
· Enables cutting with vc of 2,000m/min
· Surface finish roughness 3.2Rz (1.0Ra)
· Economical insert reduces running costs.
· Unit style enables easy runout adjustment.
· Employs safe, anti-centrifugal-force construction for high-speed conditions.
· Work material: Gray cast iron (FC250)· Cutting conditions: ap =0.5mm, fz =0.1mm/t dry· Tool grade: BN7000
Dry cutting is recommended for high speed milling of cast iron with SUMIBORON.
BN Finish Mill EASY (for high-speed finishing of cast iron)
■ Turning
● Cast iron structure and wear shape examples
Structure
FC FCD
Matrix Pearlite Pearlite + Ferrite
Tool
wea
r sh
ape
Wet
Dry
(vc=200 to 500m/min)
Work material : Continuous cutting with FC250
Tool material : BN500Tool Shape : SNGN120408Cutting Conditions : vc =450m/min
ap=0.25mm f =0.15 mm/rev Dry & Wet (water soluble)
Machine : N/C latheWork Material : FC250 200HBHolder : MTJNP2525Tool Grade : BN500Tool Shape : TNMA160408Cutting Conditions : vc=110 to 280m/min
f =0.1 mm/rev ap=0.1mm Wet
WET(Water soluble)
DRY
Surfa
ce R
ough
ness
(Rz)
(μm
) 10
8
6
4
2
0
Cutting speed (vc) (m/min)200 400Fl
ank
Wea
r Wid
th (V
B) (
mm
)
2.5 5 7.5 10 12.50
0.1
0.2
0.3
0.4
Cutting Length (km)
DryWet (water soluble)
Crater wear
For turning cast iron with SUMIBORON, cutting speeds (vc) should be 200m/min and above. Wet cutting is recommended.
Flan
k W
ear
Wid
th (m
m)
0Number of passes (Pass)
20 40 60 80 100 120 140 160 180 200
0.25
0.20
0.15
0.10
0.05
0.0
Ceramicvc = 400m/min vc = 600m/min
vc = 600m/min vc = 1,000m/min
vc = 1,500m/min
Ceramic
Num
ber
of p
asse
s
3000
50
100
150
200
250
Cutting Speed (m/min)450 600 750 900 1,050 1,200 1,350 1,500
Dry
Wet
Cutting Conditionsap=0.5mm, fz=0.15mm/t
Thermal cracks occur.
0.4 0.8 1.6 3.2
BNS800BN7000BNC500
Surface Roughness Standard Ra (μm)Good ←
Ceramic Coated carbide Cermet
Dim
ensi
onal
Tol
eran
ceG
ood
↓
1,000
500
200
1 10 20
BNS800BN7000BN500
Gray Cast Iron
Tool Life Ratio
Ceramic Coated carbide Cermet
Cut
ting
Sp
eed
(m/m
in)
500
200
1 10
Tool Life Ratio
Cut
ting
Sp
eed
(m/m
in)
Ceramic Coated carbide Cermet
Ductile Cast Iron
BNX10
BNC500
BN7000
Technical Guidance
High Speed Machining of Cast Iron with SUMIBORON, SUMIBORON Edition
N31
References
N
Parts
Technical Guidance Reference
■ Powdered Metal
Work material: Equivalent to SMF4040, ø80-ø100mm heavy interrupted facing with grooves and drilled holes. (After 40 passes)Cutting conditions: f=0.1mm/rev, ap=0.1mm WetTool Cat. No.: TNGA160404
Enables cutting at vc of up to 100m/min even with cemented carbide. However, if vc is around 120m/min or higher, wear occurs rapidly, resulting in poorer surface roughness and greater spread of burrs. On the other hand, SUMIBORON exhibits stability and superior wear resistance, burr prevention and surface roughness, especially at high speeds.
■ Heat-Resistant Alloy● Nickel based alloy
■ Hard Facing Alloys
BNS800(vc =300m/min, after 1km of cutting)
Whisker reinforced ceramic(vc =50m/min, after 0.1km of cutting)
BNS800(After 2km of cutting)
Work Material: Colmonoy No.6(NiCr-based self-fluxing alloy)
Work Material: Stellite SF-20(Co-based self-fluxing alloy)
Tool Cat. No. : SNGN090308Cutting conditions : vc=50,300m/min
f =0.1 mm/rev ap= 0.2mm Dry
Tool Cat. No. : SNGN090308Cutting conditions : vc=50m/min
f =0.1 mm/rev ap= 0.2mm Dry
Cutting conditions: f = 0.06mm/rev, ap= 0.3mm, wet★ Influence of cutting speed (Tool grade BNX20, f =0.06mm/rev, L=0.72km)
vc =300m/min vc =500m/min
★ Influence of feed rate (Tool grade BNX20, vc=300m/min, L=0.18km)
f =0.12 mm/rev f =0.06 mm/rev
★ Influence of tool grade (vc=500m/min, f =0.12 mm/rev. L=0.36km)
BNX20 BN7000
Cutting Conditions: ap= 0.3mm, Wet
Typical tool damage of CBN tool when cutting Inconel 718
12
0 50 100
10
8
6
4
2
150 200Cutting Speed (m/min)
Sur
face
Rou
ghne
ss R
z (μ
m)
0.1
0 50 100
0.2
0.3
0.4
0.5
150 200Cutting Speed (m/min) Cutting Speed (m/min)
Flan
k W
ear
Wid
th (m
m)
0 50 100
0.7
0.6
0.5
0.4
0.3
0.2
0.1
150 200
Max
imum
Hei
ght
of B
urr
(mm
)
■
■
■■
D D
D
DD
D
DD
■ ■
■
D D DD
DDDD
■■
DD
D
D
D DD D
1. Flank wear 2. Surface roughness 3. Height of burr
Flank Wear
Notch Wear
Flank Wear
Notch Wear Flank Wear
Notch Wear Flank Wear
0 500 1000 1500 2000
600
500
400
300
200
100
0
Cut
ting
Sp
eed
(m/m
in)
BN7000
BNX20
Whisker reinforced ceramic
Cutting Length (m)
Tool life criteriaNotch wear = 0.25mm ( ○ )or flank wear = 0.25mmBNX20 is recommended for high speed and low feed rates; BN7000 is recommended for cutting speeds below vc = 240m/min.
0 1000 2000 3000
600
500
400
300
200
100
0
Cut
ting
Sp
eed
(m/m
in) BN7000
BNX20
Whisker reinforced ceramic
Coated carbide (K class)
Cutting Length (m)
Tool life criteriaNotch wear = 0.25mm ( ○ )or flank wear = 0.25mmBN7000 is recommended for cutting at high feed rates (over f = 0.1mm/rev).
● Ti based alloy
Work material: Ti-6A-4VTool: NF-DNMX120404Cutting Conditions: vc=100m/min, ap=0. 1mm, f=0. 05mm/rev Wet☆ Our ultra-sharp positive SUMIDIA inserts have a strong
cutting edge and excellent wear resistance
Work material: Ti-6A-4VTool: NF-DNMX120404Cutting Conditions: vc=100m/min, ap=0. 1mm, f=0. 05mm/rev Wet☆ Our ultra-sharp positive SUMIDIA inserts have a strong
cutting edge and excellent wear resistance
Work material: Ti-6Al-4VTool: DNMA150412Cutting Conditions: vc=120m/min, ap=0. 3mm, f=0. 25mm/rev Wet☆ Highly fracture-resistant BN7000 negative insert is suitable for high-
efficiency machining with large depth of cut and high feed rate.
200
0.20
0.15
0.10
0.05
040 60
Cutting Time (min)
DA150 BreakageBN7000
Flan
k W
ear
Wid
th ( v
B) (
mm
)
50
0.12
0.10
0.08
0.06
0.04
0.02
010 15
Cutting Time (min)
BN7000 breakage
DA150
Carbide (K10)
Flan
k W
ear
Wid
th ( v
B) (
mm
)
50
0.12
0.10
0.08
0.06
0.04
0.02
010 15
Cutting Time (min)
Flan
k W
ear
Wid
th ( v
B) (
mm
)
BN7000 breakage
Carbide (K10)
DA150
0.20 0.4 0.6 0.8 1.0 1.2Cutting Distance (km)
0
0.1
0.2
0.3
0.4
0.5
Flan
k W
ear
Wid
th (m
m)
BNS800 (vc=300m/min)
Whisker reinforced ceramic (vc=50m/min)
Cutting is effectively impossible because of
the large degree of wear even at vc=50
Minimal wear at vc=300m/min
Competitor's Solid CBN(After 2km of cutting)
Chipping
0.50 1.0 2.01.5 2.5Cutting Distance (km)
0
0.02
0.04
0.06
0.08
0.10
Flan
k W
ear
Wid
th (m
m)
BNS800
Competitor's Solid CBN
Chipping
No chipping
0. 5mm
SUMIBORON Cemented Carbide CermetD ■ D
Technical Guidance
Machining Exotic Alloys with SUMIBORON, SUMIBORON Edition
Cutting conditions: f = 0.12mm/rev, ap= 0.3mm, wet
N32
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Insert Failure Cause Countermeasures
Flank Wear · Grade lacks wear resistance· Select a more wear-resistant grade (eg BNC2010, BN1000 or BN2000)
· Cutting speed is too fast
· Reduce the cutting speed to vc=200m/min or less (higher feed rate also reduces tool-to-work contact time)
· Use an insert with a larger relief angle
Crater Wear
· Grade lacks crater wear resistance
· Select a higher efficiency grade (eg BNC2010, BNX25 or BNX20)
Breakage at Bottom of Crater
· Cutting speed is too fast
· Reduce the cutting speed tovc=200m/min or less and increase the feed rate (low speed, high feed) (higher feed rate alone also reduces tool-to-work contact time)
Flaking· Grade lacks toughness · Select a tougher grade (eg BNC2020 or BN2000)
· Back force is too high
· Select an insert with a stronger cutting edge (Increase negative land angle and perform honing)
· If the grade is tough enough, improve the cutting edge sharpness
Notch Wear
· High stress at boundary
· Change to a grade with a higher notch wear resistance (e.g. BNC2010 or BN2000)
· Increase cutting speed (150 m/min or more)
· Change to the Variable Feed Rate method, which alters the feed rate in fixed output intervals
· Increase negative land angle and perform honing
Chipping at Forward Notch Position
· Impact to front cutting edge is too large or occurs constantly
· Change to a micro-grained grade with a higher fracture resistance (e.g. BNC300 and BN350)
· Increase the feed rate(higher feed rates are recommended to reduce chipping)
· Select an insert with a stronger cutting edge (Increase negative land angle and perform honing)
Chipping at Side Notch Position
· Impact to side cutting edge is too large or occurs constantly
· Change to a grade with a higher fracture resistance (e.g. BN350 or BNC300)
· Reduce feed rate
· Use an insert with a larger side cutting angle
· Use an insert with a larger nose radius
· Select an insert with a stronger cutting edge (Increase negative land angle and perform honing)
Thermal Crack
· Thermal shock is too severe
· Completely dry conditions are recommended
· Select a grade with better thermal conductivity
· Reduce cutting speed, feed rate, and depth of cut to decrease the machining load.
Technical Guidance
Cutting Edge Failure and Countermeasures when Machining Hardened Steel, SUMIBORON Edition
N33
References
N
Parts
Technical Guidance Reference
■ Basic SI Units● Quantity as a reference of SI
Quantity Material SymbolLength Metre mMass Kilogram kgTime Second s
Current Ampere ATemperature Kelvin K
Quantity of substance Mol molLuminous intensity Candela cd
● Basic unit provided with unique name and symbol (extracted)Quantity Material Symbol
Frequency Hertz HzForce Newton N
Pressure and stress Pascal PaEnergy, work, and heat quantity Joule J
Power and efficiency Watt WVoltage Bolt V
Electrical resistance Ohm Ω
■ SI Prefixes● Prefix showing integral powers of 10 combined with SI unitsCoefficient Material Symbol Coefficient Material Symbol Coefficient Material Symbol
1024 Yotta Y 103 Kilo k 10-9 Nano n1021 Zeta Z 102 Hecto h 10-12 Pico p1018 Exa E 101 Deca da 10-15 Femto f1015 Peta P 10-1 Deci d 10-18 Atto a1012 Tera T 10-2 Centi c 10-21 Zepto z109 Giga G 10-3 Milli m 10-24 Yocto y106 Mega M 10-6 Micro μ
● Specific Heat
J/(kg·K)1kcal (kg/°C) cal/
(g/°C)
1 2.38889×10-4
4.18605×103 1
● Thermal Conductivity
W/(m/K) kcal/(h·m·°C)
1 8.60000×10-1
1.16279 1
● Spindle Speed
min-1 rpm
1 1
1min-1=1rpm
● Power (efficiency and motive energy) / Thermal flow
W kgf·m/s PS kcal/h
1 1.01972×10-1 1.35962×10-3 8.60000×10-1
1×103 1.01972×102 1.35962 8.60000×102
9.80665 1 1.33333×10-2 8.43371
7.355×102 7.5×10 1 6.32529×102
1.16279 1.18572×10-1 1.58095×10-3 1
1W = 1J/s, PS: Horsepower
● Work / Energy / Heat Quantity
J kW·h kgf·m kcal
1 2.77778×10-7 1.01972×10-1 2.38889×10-4
3.60000 ×106 1 3.67098×105 8.60000×102
9.80665 2.72407×10-6 1 2.34270×10-3
4.18605 ×103 1.16279×10-3 4.26858×102 1
1J=1W/s,1J=1N/m
● Pressure
Pa(N/m2) kPa MPa GPa bar kgf/cm2 mmHg or Torr
1 1×10-3 1×10-6 1×10-9 1×10-5 1.01972×10-5 7.50062×10-3
1×103 1 1×10-3 1×10-6 1×10-2 1.01972×10-2 7.50062
1×106 1×103 1 1×10-3 1×10 1.01972×10 7.50062×103
1×109 1×106 1×103 1 1×104 1.01972×104 7.50062×106
1×105 1×102 1×10-1 1×10-4 1 1.01972 7.50062×102
9.80665×104 9.80665×10 9.80665×10-2 9.80665×10-5 9.80665×10-1 1 7.35559×102
1.33322×102 1.33322×10-1 1.33322×10-4 1.33322×10-7 1.33322×10-3 1.35951×10-3 1
1Pa = 1N/m2
● Stress
Pa(N/m2) MPa(N/mm2) kgf/mm2 kgf/cm2 kgf/m2
1 1 ×10-6 1.01972×10-7 1.01972×10-5 1.01972×10-1
1×106 1 1.01972×10-1 1.01972×10 1.01972×105
9.80665×106 9.80665 1 1×102 1×106
9.80665×104 9.80665×10-2 1×10-2 1 1×104
9.80665 9.80665×10-6 1×10-6 1×10- 4 1
1Pa = 1N/m2, 1MPa = 1N/mm2
■ Principal SI Unit Conversion List ( portions are SI units)● Force
N kgf
1 1.01972×10-1
9.80665 1
Technical Guidance
Reference: SI Unit Conversion List
N34
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■ Metals Symbols Chart (Excerpt)● Carbon Steels for Structural Use
JIS AISI DIN GB
S10C 1010 C10 10
S15C 1015 C15 15
S20C 1020 C22 20
S25C 1025 C25 25
S30C 1030 C30 30
S35C 1035 C35 35
S40C 1040 C40 40
S45C 1045 C45 45
S50C 1049 C50 50
S55C 1055 C55 55
● High Speed SteelsJIS AISI DIN GB
SKH2 T1 — W18Cr4V
SKH3 T4 S18-1-2-5 W18Cr4VCo5
SKH10 T15 S12-1-4-5 W12Cr4V5Co5
SKH51 M2 S6-5-2 W6Mo5Cr4V2
SKH52 M3-1 — W6Mo5Cr4V3
SKH53 M3-2 S6-5-3 CW6Mo5Cr4V3
SKH54 M4 — —
SKH55 — S6-5-2-5 W6Mo5Cr4V2Co5
SKH56 M36 — —
● Austenitic Stainless SteelsJIS AISI DIN GB
SUS201 201 — 1Cr17Mn6Ni5N
SUS202 202 — 1Cr18Mn8Ni5N
SUS301 301 X12CrNi17 7 1Cr17Ni7
SUS302 302 — 1Cr18Ni9
SUS302B 302B — —
SUS303 303 X10CrNiS18 9 Y1Cr18Ni9
SUS303Se 303Se — Y1Cr18Ni9Se
SUS304 304 X5CrNiS18 10 0Cr19Ni9N
SUS304L 304L X2CrNi19 11 00Cr18Ni10
SUS304NI 304N — 0Cr18Ni10
SUS305 305 X5CrNi18 12 1Cr18Ni12
SUS308 308 — —
SUS309S 309S — 0Cr23Ni13
SUS310S 310S — 0Cr25Ni20
SUS316 316 X5CrMo17 12 2 0Cr17Ni12Mo2
SUS316L 316L X2CrNiMo17 13 2 00Cr17Ni14Mo2
SUS316N 316N — 0Cr17Ni12Mo2N
SUS317 317 — 0Cr19Ni13Mo3
SUS317L 317L X2CrNiMo18 16 4 00Cr19Ni13Mo3
SUS321 321 X6CrNiTi18 10 0Cr18Ni10Ti
SUS347 347 X6CrNiNb18 10 0Cr18Ni11Nb
SUS384 384 — —
● Ni-Cr-Mo SteelsSNCM220 8620 21NiCrMo2 20CrNiMo
SNCM240 8640 — —
SNCM415 — — —
SNCM420 4320 — 20CrMo
SNCM439 4340 — 40CrNiMo, 42CrMo, 35CrMo
SNCM447 — — —
● Cr SteelsSCr415 — — 15Cr
SCr420 5120 — 20Cr
SCr430 5130 34Cr4 30Cr
SCr435 5132 37Cr4 35Cr
SCr440 5140 41Cr4 40Cr
SCr445 5147 — 45Cr
● Cr-Mo SteelsSCM415 — — 15CrMo
SCM420 — — 20CrMo
SCM430 4131 — 30CrMo
SCM435 4137 34CrMo4 35CrMo
SCM440 4140 42CrMo4 42CrMo
SCM445 4145 — —
● Mn Steels and Mn-Cr Steels for Mechanical Structures
SMn420 1522 — 20Mn2
SMn433 1534 — 30Mn2, 35Mn2
SMn438 1541 — 40Mn2
SMn443 1541 — 40Mn2, 45Mn2
SMnC420 — — 15CrMn
SMnC443 — — 40CrMn
● Carbon Tool SteelsSK1 — — T13
SK2 W1-11 1/2 — T12
SK3 W1-10 C105W1 T11
SK4 W1-9 — T10
SK5 W1-8 C80W1 T9
SK6 — C80W1 T8
SK7 — C70W2 T7
● Alloy Tool SteelsSKS11 F2 — —
SKS51 L6 — —
SKS43 W2-9 1/2 — V
SKS44 W2-8 — —
SKD1 D3 X210Cr12 Cr12
SKD11 D2 — Cr12MoV
● Gray Cast IronFC100 No 20B GG-10 HT100
FC150 No 25B GG-15 HT150
FC200 No 30B GG-20 HT200
FC250 No 35B GG-25 HT250
FC300 No 45B GG-30 HT300
FC350 No 50B GG-35 HT350
● Nodular Cast IronFCD400 60-40-18 GGG-40 QT400-18
FCD450 — GGG-40.3 QT450-10
FCD500 80-55-06 GGG-50 QT500-7
FCD600 — GGG-60 QT600-3
FCD700 100-70-03 GGG-70 QT700-2
● Ferritic Stainless SteelsSUS405 405 X10CrAl13 0CR13Al
SUS429 429 — 1Cr15
SUS430 430 X6Cr17 1Cr17
SUS430F 430F X7CrMo18 Y1Cr17
SUS434 434 X6CrMo17 1 1Cr17Mo
● Martensitic Stainless SteelsSUS403 403 — 1Cr12,1Cr17Ti
SUS410 410 X10Cr13 1Cr13
SUS416 416 — Y1Cr13
SUS420JI 420 X20Cr13 2Cr13
SUS420F 420F — Y3Cr13
SUS431 431 X20CrNi17 2 1Cr17Ni2
SUS440A 440A — 7Cr17
SUS440B 440B — 8Cr17
SUS440C 440C — 9Cr18
● Heat Resistant SteelsSUH31 — — 4Cr14Ni14W2Mo
SUH35 — — 5Cr21Mn9Ni4N
SUH36 — X53CrMnNi21 9 —
SUH37 — — 2Cr21Ni12N
SUH38 — — —
SUH309 309 — 2Cr23Ni13
SUH310 310 CrNi2520 2Cr25Ni21
SUH330 N08330 — 1Cr16Ni35
● Ferritic Heat Resistant SteelsSUH21 — CrAl1205 1Cr19Al3
SUH409 409 X6CrTi12 06Cr11Ti
SUH446 446 — 2Cr25N
● Martensitic Heat Resistant SteelsSUH1 — X45CrSi9 3 4Cr9Si2
SUH3 — — 4Cr10Si2Mo
SUH4 — — 8Cr20Si2Ni
SUH11 — — —
SUH600 — — 2Cr12MoVNbN
References
N35
References
N
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Technical Guidance Reference
■ Steel and Non-Ferrous Metal Symbols Chart (Excerpt)● Classifications and Symbols of Steels
Classification Material Symbol Code Description
Stee
l for S
truct
ure Rolled Steels for welded structures SM "M" for "Marine": Usually used in welded marine structures
Re-rolled Steels SRB "R" for "Re-rolled" and "B" for "Bar"
Rolled steel for general structures SS S for "Steel" and S for "Structure"
Light gauge sections for general structures SSC "C" for "Cold" after SS
Steel Sheets Hot rolled mild steel sheets / plates in coil form SPH P for "Plate" and "H" for "Hot"
Ste
el T
ubes
Carbon steel tubes for piping SGP "GP" for "Gas Pipe"
Carbon steel tubes for boiler and heat exchangers STB "T" for "Tube" and "B" for "Boiler·
Seamless steel tubes for high-pressure gas cylinders STH "H" for "High Pressure" after ST
Carbon steel tubes for general structures STK "K" for "Kozo" ("structure" in Japanese) after ST
Carbon steel tubes for mechanical structures STKM "M" for "Machine" after STK
Alloy steel tubes for structures STKS "S" for "Special" after STK
Alloy steel tubes for piping STPA "A" for "Alloy" after STP
Carbon steel tubes for pressure piping STPG "P" for "Piping" and "G" for "General" after ST
Carbon steel tubes for high-temperature piping STPT "T" for "Temperature" after ST
Carbon steel tubes for high-pressure piping STS "S" for "Special" after ST
Stainless steel tubes for piping SUS-TP "T" for "Tube" and "P" for "Piping" after SUS
Stee
l for
Mec
hani
cal S
truct
ures Carbon steels for mechanical structures SxxC "C" for "Carbon"
Aluminium-chromium-molybdenum steels SACM "A" for "Al", "C" for "Cr" and "M" for "Mo"
Chromium molybdenum steels SCM "C" for "Cr" and "M" for "Mo"
Chromium steels SCr "Cr" for "Chromium" after "S" for "Steel"
Nickel Chromium steels SNC "N" for "Nickel" and "C"for "Chromium"
Nickel Chromium Molybdenum steels SNCM "M" for "Molybdenum" in SNCManganese steels for mechanical structuresChromium steels
SMnSMnC
"Mn" for "Manganese""C" for "Chromium" in SMn
Sp
ecia
l Ste
els To
ol S
teel
s Carbon tool steels SK "K" for "Kogu" ("tool" in Japanese)
Hollow drill steels SKC "C" for "Chisel" after SK
Alloy tool steelSKSSKDSKT
S for "Special" after SKD for "Die" after SKT for "Tanzo" - "forging" in Japanese after SK
High-speed tool steels SKH "H" for "High speed" after SK
Sta
inle
ss S
teel Free cutting sulphuric steels SUM "M" for "Machinability" after SU
High-carbon chromium bearing steels SUJ "J" for "Jikuuke" ("bearing" in Japanese) after SU
Spring steels SUP "P" for "Spring" after SU
Stainless Steel SUS "S" for "Stainless Steel" after SU
Heat-
resista
nt Ste
el
Heat-resistant Steel SUH "U" for "Special Usage" and "H" for "Heat"
Heat-resistant steel bars SUH-B "B" for "Bar" after SUH
Heat-resistant steel sheets SUHP "P" for "Plate" after SUH
Forg
ed S
teel
s Carbon steel forgings for general use SF "F" for "Forging"
Carbon steel booms and billets for forgings SFB "B" for "Billet" after SF
Chromium molybdenum steel forgings SFCM "C" for "Chromium" and "M" for "Molybdenum" after SF
Nickel Chromium Molybdenum steel forgings SFNCM "N" for "Nickel" in SFCM
Cas
t Iro
n
Gray cast iron FC "F" for "Ferrous" and "C" for "Casting"
Spherical graphite / Ductile cast irons FCD "D" for "Ductile" after FC
Blackheart malleable cast irons FCMB "M" for "Malleable" and "B" for "Black" after FC
Whiteheart malleable cast irons FCMW "W" for "White" after FCM
Pearlite malleable cast iron FCMP "P" for "Pearlite" after FCM
Cas
t S
teel
s Carbon cast steels SC "C" for "Casting"
Cast stainless steels SCS "S" for "Stainless Steel" after SC
Heat-resistant cast steels SCH "H" for "Heat" after SC
High-manganese cast steels SCMnH "Mn" for "Manganese" and "H" for "High" after SC
● Non-Ferrous Metals
Classification Material Symbol
Cop
per a
nd C
oppe
r Allo
ys
Copper and copper alloys - sheets, plates and strips
CxxxxP
CxxxxPP
CxxxxR
Copper and copper alloys - welded pipes and tubes
CxxxxBD
CxxxxBDS
CxxxxBE
CxxxxBF
Alum
inum
and
Alu
min
um A
lloys Aluminum and Al alloys - Sheets,
plates and strips
AxxxxP
AxxxxPC
Aluminum and Al alloysRods, bars, and wires
AxxxxBE
AxxxxBD
AxxxxW
Aluminum and Al alloys - Extruded shapes AxxxxS
Aluminum and Al alloy castingsAxxxxFD
AxxxxFH
Wrough
t Alloys
Ma
gnesium Magnesium alloy sheets and plates MP
Mat
eria
l Ni
ckel Nickel-copper alloy sheets and plates NCuP
Nickel-copper alloy rods and bars NCuBWro
ught Ma
terials
Titanium Titanium rods and bars TB
Cas
tings
Brass castings YBsCx
High-strength brass castings HBsCx
Bronze castings BCx
Phosphorus Bronze castings PBCx
Aluminum bronze castings AlBCx
Aluminum alloy castings AC
Magnesium alloy castings MC
Zinc alloy die castings ZDCx
Aluminum alloy die castings ADC
Magnesium alloy die castings MDC
White metals WJ
Aluminum alloy castings for bearings AJ
Copper-lead alloy castings for bearings KJ
References
N36
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■ Hardness Scale Comparison Chart ● Approximate corresponding values for steel hardness on the Brinell scale
Brinell 3,000kgf
HB
Rockwell Hardness
Vickers 50kgf
HV
Shore Hardness
HS
Tensile Strength
(GPa)
A Scale 60kgf brale
HRA
B Scale 100kgf 1/10in
ball HRB
C Scale 150kgf brale
HRC
D Scale 100kgf brale
HRD
— 85.6 — 68.0 76.9 940 97 —
— 85.3 — 67.5 76.5 920 96 —
— 85.0 — 67.0 76.1 900 95 —
767 84.7 — 66.4 75.7 880 93 —
757 84.4 — 65.9 75.3 860 92 —
745 84.1 — 65.3 74.8 840 91 —
733 83.8 — 64.7 74.3 820 90 —
722 83.4 — 64.0 73.8 800 88 —
712 — — — — — — —
710 83.0 — 63.3 73.3 780 87 —
698 82.6 — 62.5 72.6 760 86 —
684 82.2 — 61.8 72.1 740 — —
682 82.2 — 61.7 72.0 737 84 —
670 81.8 — 61.0 71.5 720 83 —
656 81.3 — 60.1 70.8 700 — —
653 81.2 — 60.0 70.7 697 81 —
647 81.1 — 59.7 70.5 690 — —
638 80.8 — 59.2 70.1 680 80 —
630 80.6 — 58.8 69.8 670 — —
627 80.5 — 58.7 69.7 667 79 —
601 79.8 — 57.3 68.7 640 77 —
578 79.1 — 56.0 67.7 615 75 —
555 78.4 — 54.7 66.7 591 73 2.06
534 77.8 — 53.5 65.8 569 71 1.98
514 76.9 — 52.1 64.7 547 70 1.89
495 76.3 — 51.0 63.8 528 68 1.82
477 75.6 — 49.6 62.7 508 66 1.73
461 74.9 — 48.5 61.7 491 65 1.67
444 74.2 — 47.1 60.8 472 63 1.59
429 73.4 — 45.7 59.7 455 61 1.51
415 72.8 — 44.5 58.8 440 59 1.46
401 72.0 — 43.1 57.8 425 58 1.39
388 71.4 — 41.8 56.8 410 56 1.33
375 70.6 — 40.4 55.7 396 54 1.26
363 70.0 — 39.1 54.6 383 52 1.22
352 69.3 (110.0) 37.9 53.8 372 51 1.18
341 68.7 (109.0) 36.6 52.8 360 50 1.13
331 68.1 (108.5) 35.5 51.9 350 48 1.10
Brinell 3,000kgf
HB
Rockwell Hardness
Vickers 50kgf
HV
Shore Hardness
HS
Tensile Strength
(GPa)
A Scale 60kgf brale
HRA
BScale
100kgf 1/10in
ball HRB
C Scale 150kgf brale
HRC
D Scale 100kgf brale
HRD
321 67.5 (108.0) 34.3 50.1 339 47 1.06
311 66.9 (107.5) 33.1 50.0 328 46 1.03
302 66.3 (107.0) 32.1 49.3 319 45 1.01
293 65.7 (106.0) 30.9 48.3 309 43 0.97
285 65.3 (105.5) 29.9 47.6 301 — 0.95
277 64.6 (104.5) 28.8 46.7 292 41 0.92
269 64.1 (104.0) 27.6 45.9 284 40 0.89
262 63.6 (103.0) 26.6 45.0 276 39 0.87
255 63.0 (102.0) 25.4 44.2 269 38 0.84
248 62.5 (101.0) 24.2 43.2 261 37 0.82
241 61.8 100.0 22.8 42.0 253 36 0.80
235 61.4 99.0 21.7 41.4 247 35 0.78
229 60.8 98.2 20.5 40.5 241 34 0.76
223 — 97.3 (18.8) — 234 — —
217 — 96.4 (17.5) — 228 33 0.73
212 — 95.5 (16.0) — 222 — 0.71
207 — 94.6 (15.2) — 218 32 0.69
201 — 93.8 (13.8) — 212 31 0.68
197 — 92.8 (12.7) — 207 30 0.66
192 — 91.9 (11.5) — 202 29 0.64
187 — 90.7 (10.0) — 196 — 0.62
183 — 90.0 (9.0) — 192 28 0.62
179 — 89.0 (8.0) — 188 27 0.60
174 — 87.8 (6.4) — 182 — 0.59
170 — 86.8 (5.4) — 178 26 0.57
167 — 86.0 (4.4) — 175 — 0.56
163 — 85.0 (3.3) — 171 25 0.55
156 — 82.9 (0.9) — 163 — 0.52
149 — 80.8 — — 156 23 0.50
143 — 78.7 — — 150 22 0.49
137 — 76.4 — — 143 21 0.46
131 — 74.0 — — 137 — 0.45
126 — 72.0 — — 132 20 0.43
121 — 69.8 — — 127 19 0.41
116 — 67.6 — — 122 18 0.40
111 — 65.7 — — 117 15 0.381) Figures within the ( ) are not commonly used.
2) Rockwell A, C and D scales utilise a diamond brale.
3) This chart was taken from the JIS Iron and Steel Handbook (1980).
References
N37
References
N
Parts
Technical Guidance Reference
■ Standard of Tapers ● Morse Taper
● Bottle Grip Taper
● Bottle Grip Taper (Units: mm)
Taper No.D
(Standard Dimensions)D1 D2 t1 t2 t3 t4 t5 d2 d3 L B L3 L4 g b1 t7 Fig
BT30 31.75 46 38 20 8 13.6 2 2 14 12.5 48.4 24 7 17 M12 16.1 16.3
3
BT35 38.10 53 43 22 10 14.6 2 2 14 12.5 56.4 24 7 20 M12 16.1 19.6
BT40 44.45 63 53 25 10 16.6 2 2 19 17 65.4 30 8 21 M16 16.1 22.6
BT45 57.15 85 73 30 12 21.2 3 3 23 21 82.8 36 9 26 M20 19.3 29.1
BT50 69.85 100 85 35 15 23.2 3 3 27 25 101.8 45 11 31 M24 25.7 35.4BT60 107.95 155 135 45 20 28.2 3 3 33 31 161.8 56 12 34 M30 25.7 60.1
(Unit: mm)
Morse Taper
NumberTaper (1)
Taper Angle ( α )
Taper TangFig
D aD1(2)
(approx.)d1(2)
(approx.)N
(Max)B
(Max)d2
(Max)b
C (Max)
e (Max)
R r
0 0.05205 1°29'27" 9.045 3 9.2 6.1 56.5 59.5 6.0 3.9 6.5 10.5 4 1
1
1 0.04988 1°25'43" 12.065 3.5 12.2 9.0 62.0 65.5 8.7 5.2 8.5 13.5 5 1.22 0.04995 1°25'50" 17.780 5 18.0 14.0 75.0 80.0 13.5 6.3 10 16 6 1.63 0.05020 1°26'16" 23.825 5 24.1 19.1 94.0 99.0 18.5 7.9 13 20 7 24 0.05194 1°29'15" 31.267 6.5 31.6 25.2 117.5 124.0 24.5 11.9 16 24 8 2.55 0.05263 1°30'26" 44.399 6.5 44.7 36.5 149.5 156.0 35.7 15.9 19 29 10 36 0.05214 1°29'36" 63.348 8 63.8 52.4 210.0 218.0 51.0 19.0 27 40 13 47 0.05200 1°29'22" 83.058 10 83.6 68.2 286.0 296.0 66.8 28.6 35 54 19 5
● American Standard Taper (National Taper)
119.212
120.047
120.020
119.922
119.245
119.002
119.180
119.231
Morse Taper
NumberTaper (1)
Taper Angle ( α )
Taper ThreadFig
D aD1(2)
(approx.)d1(2)
(approx.)N
(Max)B
(Max)d2
(Max)d3
K (Min)
t (Max)
r
0 0.05205 1°29'27" 9.045 3 9.2 6.4 50 53 6 - - 4 0.2
2
1 0.04988 1°25'43" 12.065 3.5 12.2 9.4 53.5 57 9 M 6 16 5 0.22 0.04995 1°25'50" 17.780 5 18.0 14.6 64 69 14 M10 24 5 0.23 0.05020 1°26'16" 23.825 5 24.1 19.8 81 86 19 M12 28 7 0.64 0.05194 1°29'15" 31.267 6.5 31.6 25.9 102.5 109 25 M16 32 9 15 0.05263 1°30'26" 44.399 6.5 44.7 37.6 129.5 136 35.7 M20 40 9 2.56 0.05214 1°29'36" 63.348 8 63.8 53.9 182 190 51 M24 50 12 47 0.05200 1°29'22" 83.058 10 83.6 70.0 250 260 65 M33 80 18.5 5
Note (1) The fractional values are the taper standards. (2) Diameters D1 and d1 are calculated from the diameter D value, the taper, a, and M1 and rounded up to one decimal place.
Remark 1. Tapers are measured using JIS B 3301 ring gauges. At least 75% must be correct. 2. Screws must have metric coarse screw thread as per JIS B 0205 and Class 3 precision as per JIS B 0209.
BL3
L
g
t1
t5t2t3
t4
L4
t7
D1
D2
60°
d2
d3
øD
b17/24 Taper
b1
E NB
K
r
ta
ød3
ød2
ød1
øD1
øD 60°
eNB
E r
R8°18'
a
C
bød
1
ød2
øD1
øD
N
BL3
60°
ød1
øg
tL a
b
7/24 Taper
øD
Fig.2 Drawing Thread TypeFig.1 With Tang
● American Standard Taper (National Taper) (Units: mm)
Taper No. Nominal Dimensions D d1 L L1 (Min.) L2 (Min.) L3 (Min.) g a t b Fig
30 11/4" 31.750 17.4 68.4 48.4 24 34 1/2" 1.6 15.9 16
440 13/4" 44.450 25.3 93.4 65.4 32 43 5/8" 1.6 15.9 22.5
50 23/4" 69.850 39.6 126.8 101.8 47 62 1" 3.2 25.4 35
60 41/4" 107.950 60.2 206.8 161.8 59 76 11/4" 3.2 25.4 60
-0.29-0.36-0.30-0.384-0.31-0.41-0.34-0.46
Fig 3 Fig 4
119.212
120.047
120.020
119.922
119.254
119.002
119.180
119.231
References
N38
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■ Dimensional Tolerance of Standard Fittings [Excerpt from JIS B 0401 (1999)] ● Dimensional Tolerance Used for Shafts of Standard FittingsClassification of Reference Dimensions (mm)
Shaft Tolerance Class Unit: μm
or greater or less b9 c9 d8 d9 e7 e8 e9 f6 f7 f8 g5 g6 h5 h6 h7 h8 h9 js5 js6 js7 k5 k6 m5 m6 n6 p6 r6 s6 t6 u6 x6
— 3 -140-165
-60-85
-20-34
-20-45
-14-24
-14-28
-14-39
-6-12
-6-16
-8-20
-2-6
-2-8
0-4
0-6
0-10
0-14
0-25 ±2 ±3 ±5
+40
+60
+6+2
+8+2
+10+4
+12+6
+16+10
+20+14 — +24
+18+26+20
3 6 -140-170
-70-100
-30-48
-30-60
-20-32
-20-38
-20-50
-10-18
-10-22
-10-28
-4-9
-4-12
0-5
0-8
0-12
0-18
0-30 ±2.5 ±4 ±6
+6+1
+9+1
+9+4
+12+4
+16+8
+20+12
+23+15
+27+19 — +31
+23+36+28
6 10 -150-186
-80-116
-40-62
-40-76
-25-40
-25-47
-25-61
-13-22
-13-28
-13-35
-5-11
-5-14
0-6
0-9
0-15
0-22
0-36 ±3 ±4.5 ±7.5
+7+1
+10+1
+12+6
+15+6
+19+10
+24+15
+28+19
+32+23 — +37
+28+43+34
10 14-150-193
-95-138
-50-77
-50-93
-32-50
-32-59
-32-75
-16-27
-16-34
-16-43
-6-14
-6-17
0-8
0-11
0-18
0-27
0-43 ±4 ±5.5 ±9
+9+1
+12+1
+15+7
+18+7
+23+12
+29+18
+34+23
+39+28 — +44
+33
+51+40
14 18 +56+45
18 24-160-212
-110-162
-65-98
-65-117
-40-61
-40-73
-40-92
-20-33
-20-41
-20-53
-7-16
-7-20
0-9
0-13
0-21
0-33
0-52 ±4.5 ±6.5 ±10.5
+11+2
+15+2
+17+8
+21+8
+28+15
+35+22
+41+28
+48+35
— +54+41
+67+54
24 30 +54+41
+61+48
+77+64
30 40 -170-232
-120-182 -80
-119-80
-142-50-75
-50-89
-50-112
-25-41
-25-50
-25-64
-9-20
-9-25
0-11
0-16
0-25
0-39
0-62 ±5.5 ±8 ±12.5
+13+2
+18+2
+20+9
+25+9
+33+17
+42+26
+50+34
+59+43
+64+48
+76+60
—40 50 -180
-242-130-192
+70+54
+86+70
50 65 -190-264
-140-214 -100
-146-100-174
-60-90
-60-106
-60-134
-30-49
-30-60
-30-76
-10-23
-10-29
0-13
0-19
0-30
0-46
0-74 ±6.5 ±9.5 ±15
+15+2
+21+2
+24+11
+30+11
+39+20
+51+32
+60+41
+72+53
+85+66
+106+87
—65 80 -200
-274-150-224
+62+43
+78+59
+94+75
+121+102
80 100 -220-307
-170-257 -120
-174-120-207
-72-107
-72-126
-72-159
-36-58
-36-71
-36-90
-12-27
-12-34
0-15
0-22
0-35
0-54
0-87 ±7.5 ±11 ±17.5
+18+3
+25+3
+28+13
+35+13
+45+23
+59+37
+73+51
+93+71
+113+91
+146+124
—100 120 -240
-327-180-267
+76+54
+101+79
+126+104
+166+144
120 140 -260-360
-200-300
-145-208
-145-245
-85-125
-85-148
-85-185
-43-68
-43-83
-43-106
-14-32
-14-39
0-18
0-25
0-40
0-63
0-100 ±9 ±12.5 ±20
+21+3
+28+3
+33+15
+40+15
+52+27
+68+43
+88+63
+117+92
+147+122
— —140 160 -280-380
-210-310
+90+65
+125+100
+159+134
160 180 -310-410
-230-330
+93+68
+133+108
+171+146
180 200 -340-455
-240-355
-170-242
-170-285
-100-146
-100-172
-100-215
-50-79
-50-96
-50-122
-15-35
-15-44
0-20
0-29
0-46
0-72
0-115±10 ±14.5 ±23
+24+4
+33+4
+37+17
+46+17
+60+31
+79+50
+106+77
+151+122
— — —200 225 -380-495
-260-375
+109+80
+159+130
225 250 -420-535
-280-395
+113+84
+169+140
250 280 -480-610
-300-430 -190
-271-190-320
-110-162
-110-191
-110-240
-56-88
-56-108
-56-137
-17-40
-17-49
0-23
0-32
0-52
0-81
0-130±11.5 ±16 ±26
+27+4
+36+4
+43+20
+52+20
+66+34
+88+56
+126+94
— — — —280 315 -540
-670-330-460
+130+98
315 355 -600-740
-360-500 -210
-299-210-350
-125-182
-125-214
-125-265
-62-98
-62-119
-62-151
-18-43
-18-54
0-25
0-36
0-57
0-89
0-140±12.5 ±18 ±28.5
+29+4
+40+4
+46+21
+57+21
+73+37
+98+62
+144+108
— — — —355 400 -680
-820-400-540
+150+114
400 450 -760-915
-440-595 -230
-327-230-385
-135-198
-135-232
-135-290
-68-108
-68-131
-68-165
-20-47
-20-60
0-27
0-40
0-63
0-97
0-155±13.5 ±20 ±31.5
+32+5
+45+5
+50+23
+63+23
+80+40
+108+68
+166+126
— — — —450 500 -840
-995-480-635
+172+132
References
N39
References
N
Parts
Technical Guidance Reference
■ Dimensional Tolerance of Standard Fittings [Excerpt from JIS B 0401 (1999)] ● Dimensional Tolerance Used for Holes of Standard FittingsClassification of Reference Dimensions (mm)
Hole Tolerance Class Unit: μm
or greater or less B10 C9 C10 D8 D9 D10 E7 E8 E9 F6 F7 F8 G6 G7 H6 H7 H8 H9 H10JS6 JS7 K6 K7 M6M7 N6 N7 P6 P7 R7 S7 T7 U7 X7
— 3 +180+140
+85+60
+100+60
+34+20
+45+20
+60+20
+24+14
+28+14
+39+14
+12+6
+16+6
+20+6
+8+2
+12+2
+60
+100
+140
+250
+400 ±3 ±5 0
-60
-10-2-8
-2-12
-4-10
-4-14
-6-12
-6-16
-10-20
-14-24 — -18
-28-20-30
3 6 +188+140
+100+70
+118+70
+48+30
+60+30
+78+30
+32+20
+38+20
+50+20
+18+10
+22+10
+28+10
+12+4
+16+4
+80
+120
+180
+300
+480 ±4 ±6 +2
-6+3-9
-1-9
0-12
-5-13
-4-16
-9-17
-8-20
-11-23
-15-27 — -19
-31-24-36
6 10 +208+150
+116+80
+138+80
+62+40
+76+40
+98+40
+40+25
+47+25
+61+25
+22+13
+28+13
+35+13
+14+5
+20+5
+90
+150
+220
+360
+580 ±4.5 ±7.5 +2
-7+5
-10-3
-120
-15-7
-16-4
-19-12-21
-9-24
-13-28
-17-32 — -22
-37-28-43
10 14+220+150
+138+95
+165+95
+77+50
+93+50
+120+50
+50+32
+59+32
+75+32
+27+16
+34+16
+43+16
+17+6
+24+6
+110
+180
+270
+430
+700 ±5.5 ±9 +2
-9+6
-12-4
-150
-18-9
-20-5
-23-15-26
-11-29
-16-34
-21-39 — -26
-44
-33-51
14 18 -38-56
18 24+244+160
+162+110
+194+110
+98+65
+117+65
+149+65
+61+40
+73+40
+92+40
+33+20
+41+20
+53+20
+20+7
+28+7
+130
+210
+330
+520
+840 ±6.5 ±10.5 +2
-11+6
-15-4
-170
-21-11-24
-7-28
-18-31
-14-35
-20-41
-27-48
— -33-54
-46-67
24 30 -33-54
-40-61
-56-77
30 40 +270+170
+182+120
+220+120 +119
+80+142+80
+180+80
+75+50
+89+50
+112+50
+41+25
+50+25
+64+25
+25+9
+34+9
+160
+250
+390
+620
+1000 ±8 ±12.5 +3
-13+7
-18-4
-200
-25-12-28
-8-33
-21-37
-17-42
-25-50
-34-59
-39-64
-51-76
—40 50 +280
+180+192+130
+230+130
-45-70
-61-86
50 65 +310+190
+214+140
+260+140 +146
+100+174+100
+220+100
+90+60
+106+60
+134+60
+49+30
+60+30
+76+30
+29+10
+40+10
+190
+300
+460
+740
+1200 ±9.5 ±15 +4
-15+9
-21-5
-240
-30-14-33
-9-39
-26-45
-21-51
-30-60
-42-72
-55-85
-76-106
—65 80 +320
+200+224+150
+270+150
-32-62
-48-78
-64-94
-91-121
80 100 +360+220
+257+170
+310+170 +174
+120+207+120
+260+120
+107+72
+126+72
+159+72
+58+36
+71+36
+90+36
+34+12
+47+12
+220
+350
+540
+870
+1400 ±11 ±17.5 +4
-18+10-25
-6-28
0-35
-16-38
-10-45
-30-52
-24-59
-38-73
-58-93
-78-113
-111-146
—100 120 +380
+240+267+180
+320+180
-41-76
-66-101
-91-126
-131-166
120 140 +420+260
+300+200
+360+200
+208+145
+245+145
+305+145
+125+85
+148+85
+185+85
+68+43
+83+43
+106+43
+39+14
+54+14
+250
+400
+630
+1000
+1600 ±12.5 ±20 +4
-21+12-28
-8-33
0-40
-20-45
-12-52
-36-61
-28-68
-48-88
-77-117
-107-147
— —140 160 +440+280
+310+210
+370+210
-50-90
-85-125
-119-159
160 180 +470+310
+330+230
+390+230
-53-93
-93-133
-131-171
180 200 +525+340
+355+240
+425+240
+242+170
+285+170
+355+170
+146+100
+172+100
+215+100
+79+50
+96+50
+122+50
+44+15
+61+15
+290
+460
+720
+1150
+1850 ±14.5 ±23 +5
-24+13-33
-8-37
0-46
-22-51
-14-60
-41-70
-33-79
-60-106
-105-151
— — —200 225 +565+380
+375+260
+445+260
-63-109
-113-159
225 250 +605+420
+395+280
+465+280
-67-113
-123-169
250 280 +690+480
+430+300
+510+300 +271
+190+320+190
+400+190
+162+110
+191+110
+240+110
+88+56
+108+56
+137+56
+49+17
+69+17
+320
+520
+810
+1300
+2100 ±16 ±26 +5
-27+16-36
-9-41
0-52
-25-57
-14-66
-47-79
-36-88
-74-126
— — — —280 315 +750
+540+460+330
+540+330
-78-130
315 355 +830+600
+500+360
+590+360 +299
+210+350+210
+440+210
+182+125
+214+125
+265+125
+98+62
+119+62
+151+62
+54+18
+75+18
+360
+570
+890
+1400
+2300 ±18 ±28.5 +7
-29+17-40
-10-46
0-57
-26-62
-16-73
-51-87
-41-98
-87-144
— — — —355 400 +910
+680+540+400
+630+400
-93-150
400 450 +1010+760
+595+440
+690+440 +327
+230+385+230
+480+230
+198+135
+232+135
+290+135
+108+68
+131+68
+165+68
+60+20
+83+20
+400
+630
+970
+1550
+2500 ±20 ±31.5 +8
-32+18-45
-10-50
0-63
-27-67
-17-80
-55-95
-45-108
-103-166
— — — —450 500 +1090
+840+635+480
+730+480
-109-172
References
N40
Refe
renc
es
N
Par
tsTe
chnic
al Gu
idanc
e Re
feren
ce
■ Dimensional Tolerance and Fittings [Excerpt from JIS B 0401 (1999)] ● Standard Fitting for Holes
Reference Hole
Shaft Tolerance Class
Gap fitting Intermediate fitting Tight fitting
H6g5 h5 js5 k5 m5
f6 g6 h6 js6 k6 m6 n6* p6*
H7f6 g6 h6 js6 k6 m6 n6 p6* r6* s6 t6 u6 x6
e7 f7 h7 js7
H8
f7 h7
e8 f8 h8
d9 e9
H9d8 e8 h8
c9 d9 e9 h9
H10 b9 c9 d9
Note: *Exceptions may arise with these fittings depending on the dimension category.
● Standard Fittings for Shafts
Reference Shaft
Hole Tolerance Class
Gap fitting Intermediate fitting Tight fitting
h5 H6 JS6 K6 M6 N6* P6
h6F6 G6 H6 JS6 K6 M6 N6 P6*
F7 G7 H7 JS7 K7 M7 N7 P7* R7 S7 T7 U7 X7
h7E7 F7 H7
F8 H8
h8D8 E8 F8 H8
D9 E9 H9
h9
D8 E8 H8
C9 D9 E9 H9
B10 C10 D10
Note: *Exceptions may arise with these fittings depending on the dimension category.
● Correlation of Tolerance Zones in Standard Hole Fittings
Note: The above table is for reference dimensions greater than 18mm up to 30mm.
● Correlation of Tolerance Zones in Standard Shaft Fittings
Note: The above table is for reference dimensions greater than 18mm up to 30mm.
Reference Hole Reference Shaft
Fitting
Shaft Tolerance Class
Fitting
Hole Tolerance Class
H6 H7 H8 H9 h5 h6 h7 h8 h9H10
Gap
fitt
ing
Interm
ediat
e fittin
g
Tigh
t fit
ting
Gap
fitt
ing
Tigh
t fit
ting
Gap
fitt
ing
Gap
fitt
ing
Gap
fitt
ing
Gap
fitt
ing
Gap
fitt
ing
Inte
rmed
iate
fit
ting
Tigh
t fit
ting
Inter
med
iate fi
tting
Gap
fitt
ing
Slid
ing
Gap fitting Gap fittingIntermediate fitting Tight fitting
50 200
150
100
50
0
0
-50
-100
-150
-200 -50
Dim
ensi
onal
tol
eran
ce (μ
m)
Dim
ensi
onal
tol
eran
ce (μ
m)
f6 g5 g6 h5 h6 js5 js6k5 k6 m5 m6 n6 p6 e7 f6 f7 g6 h6 h7 js6 js7 k6m6n6 p6 r6 s6 t6 u6 x6 d9 e8 e9 f7 f8 h7 h8 c9 d8 d9g8 e9 h8 h9 b9 c9 d9 M6 JS6 K5 M6 N6 P6 F6 F7 G6 G7 H6 H7 JS6 JS7 K6 K7 M6 M7 N6 N7 P6 P7 R7 S7 T7 U7 X7 E7 F7 F8 H7 H8 D8 D9 E8 E9 F8 H8 H9 B10 C9 C10 D8 D9 D10 E8 E9 H8 H9
Driv
ing
Pre
ss fi
ttin
g
Reinf
orce
d pr
ess fi
tting
Sh
rin
kag
e fi
ttin
g
Loos
e ro
tary
fitti
ngLi
ght r
otar
y fit
ting
Ro
tary
fitt
ing
H10
H9
H8H7H6
h5h6 h6
h7h8
h9
References
N41
References
N
Parts
Technical Guidance Reference
■ Surface Roughness ● Types and Definitions of Typical Surface Roughness
Type Symbol Method of Determination Descriptive Figure
R M
ax.
*1)
Rz
This value is found by extracting the reference length in the mean line direction from the surface roughness curve, measuring the intervals between the peaks and valleys in the extracted area in the longitudinal magnification direction of the surface roughness curve, and expressing this value in micrometres (μm). Remarks: When finding Rz,
any areas deemed to be scratches are removed before extracting the reference length from an area with no high peaks or low valleys.
LR
p
Rz
Rv
m
Rz=Rp+Rv
Cal
cula
ted
Rou
ghne
ss
Ra
This value is found by extracting the reference length in the mean line direction from the roughness curve, taking the average line direction of the extracted area as the X-axis and the longitudinal magnification direction as the Y-axis and expressing the value found by the equation below in micrometres (μm) with the roughness curve expressed by y=f(x).
L
Ra
m
L
L
Ra= {f(x)}dx10
10-p
oint
Ave
rage
Rou
ghne
ss
*2)
Rz JIS
This value is found by extracting the reference length in the mean line direction from the roughness curve, finding the sum of the mean absolute peak height taken from the five highest peaks (Yp) and the mean absolute valley height taken from the five lowest valleys (Yv) measured in the longitudinal magnification direction from the average line direction of the extracted area and expressing this value in micrometres (μm).
L
Yp1
Yp2
Yp3
Yp4
Yp5
Yv1 Yv2 Yv3
Yv4 Yv5
m
(Yp1+Yp2+Yp3+Yp4+Yp5)+(Yv1+Yv2+Yv3+Yv4+Yv5)5
RzJIS=
Designated values for the above types of maximum height (Rz)*1), 10-point average roughness
(Rz JIS)*2), calculated average roughness (Ra) classifications, and reference length Mare shown on
the table at right with triangular symbols.
*1) The maximum height symbol (Rz) is calculated according to the new JIS B 0601:2001 standard.
(This value was Ry under the old standard.) *2) The 10-point average roughness (Rz JIS) is calculated according to the new JIS B 0601:2001
standard. (This value was Rz under the old standard.)
● Relationship with triangular symbol display
Designated values for maximum
height *1)
(Rz)
Designated values for calculated average
roughness (Ra)
Designated values for 10-point average
roughness *2)
(RzJIS)
Standard reference L length value
(mm)
* Triangular Symbols
(0.05)0.10.20.4
(0.012)0.0250.050.10
(0.05)0.10.20.4
0.25
0.8 0.20 0.8
1.63.26.3
0.400.801.6
1.63.26.3
0.8
12.5(18)25
3.26.3
12.5(18)25
2.5
(35)50(70)100
12.525
(35)50(70)100
8
(140) 200 (280) 400 (560)
(50)(100)
(140)200(280)400(560)
— —
Remarks: The designated values in ( ) do not apply unless otherwise stated.* Finish symbols (triangular symbol ( ▽ ) and tilde (~)) were
removed from JIS in the 1994 revision.
JJJJ
JJJ
JJ
J
References
N42
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